Replacing Fuel Pump In 2006 Town And Country: Step-By-Step Guide

Replacing the fuel pump on a 2006 Town and Country vehicle can be a challenging task. The fuel pump is located inside the fuel tank, and to access it, one may need to remove the fuel tank or, alternatively, cut a hole in the floor above the gas tank. Before beginning any repairs, it is crucial to relieve the pressure from the system and disconnect the negative battery cable. Additionally, it is important to clean the outside of the tank and capture any fuel that may bleed off safely. When removing the fuel tank, one must be cautious not to spill any fuel and carefully disconnect all relevant hoses and wires. After accessing the fuel pump, one can remove it by tapping the fuel pump lock-ring counter-clockwise with a hammer and a brass drift and then pulling out the pump. Finally, a new fuel pump can be installed, and the fuel tank can be reattached, ensuring all connections are secure.

Release fuel pressure and disconnect the negative battery cable

To replace the fuel pump on a 2006 Town and Country, you must first release the fuel pressure and disconnect the negative battery cable. Here is a detailed, step-by-step guide:

• Release Fuel Pressure: Before starting any repairs, it is crucial to relieve the pressure from the fuel system. This can be done by using the relief valve on the pressure gauge. Always be cautious and catch any fuel that may bleed off the system, disposing of it properly.
• Disconnect the Negative Battery Cable: Ensure that you disconnect the negative battery cable before proceeding. If the battery cable is corroded, clean the terminal and cable for optimal performance and to prevent further issues.

These initial steps are essential for safety and to ensure that the fuel system is ready for the fuel pump replacement. Now, you can move on to the next steps, which involve accessing the fuel pump and its components. Remember to refer to a qualified mechanic or a professional repair guide for a comprehensive, step-by-step procedure to replace the fuel pump on your 2006 Town and Country.

Remove the fuel tank

To remove the fuel tank from a 2006 Town and Country, follow these steps:

First, relieve the pressure from the system. Do this by using the relief valve on the pressure gauge. Remember to catch any fuel that may bleed off the system and dispose of it properly. Next, disconnect the negative battery cable. If the battery cable is corroded, clean the terminal and cable before reinstalling.

Remove the shield to access the fuel filler hose and vent line. Disconnect the vent line and loosen the clamp on the fuel filler hose. Remove the hose as the tank is lowered. Then, disconnect the main fuel line. There may be residual pressure at this point, so be sure to capture any fuel in a safe container.

Now you are ready to lower the fuel tank. Disconnect the static ground attached to the tank (it goes to the fuel filter) and remember to reattach it later. As you lower the tank, you will need to remove the emissions tubes, which run through the frame support. Once the tank is partially lowered, disconnect the electrical connection.

Slide the safety retainer over to the right to prevent debris from getting into the tank. Clean the outside of the tank with a mild detergent and water.

Disconnect the fuel lines, which are pinch-type connectors. Remove the retainer to reuse it on the new module.

At this point, the tank is ready to be removed from the vehicle. Remember to disconnect the fuel pump module electrical connector and place the retainer in the unlocked position. You may need to raise the vehicle to access the tank.

Remove the fuel pump lock-ring and O-ring

To remove the fuel pump lock-ring and O-ring from your 2006 Town and Country, you will first need to remove the fuel tank. It is important to note that the fuel system is under constant pressure, even when the engine is off. Therefore, always release the fuel system pressure before servicing any fuel system component.

Once the fuel tank has been removed, you can access the fuel pump lock-ring and O-ring. Here are the steps to remove them:

• Using a hammer and a brass drift, carefully tap the fuel pump lock-ring counter-clockwise to release it. Be careful not to overtighten the lock-ring, as this can cause the fuel pump seal to split and leak.
• With the lock-ring loosened, you can now remove the fuel pump and its O-ring from the fuel tank. It is important to discard the old O-ring and replace it with a new one during reassembly.
• Before removing the fuel pump and O-ring, cover the tank openings to prevent dirt from entering the system.

If you are having difficulty removing the lock-ring, it may be seized due to rust or corrosion. In this case, you can try the following methods to help loosen it:

• Soak the lock-ring with penetrating oil, such as WD-40 or PB Blaster, and let it sit for a few minutes before attempting to remove it again.
• Use a flat-head screwdriver and a hammer to gently tap the lock-ring tabs in a counter-clockwise direction. Alternate between different tabs to distribute the force evenly.
• Get a helper to use a second screwdriver and hammer to tap the opposite tabs at the same time.
• Use a brass drift punch instead of a screwdriver to avoid damaging the tabs.
• If you are still unable to remove the lock-ring, you may need to use an air hammer or impact hammer for more force.

Remember to work carefully and avoid using excessive force, as you do not want to damage the fuel tank or create sparks that could ignite fuel fumes.

Clean the tank and install a new O-ring seal

To clean the tank and install a new O-ring seal on a 2006 Town and Country, follow these steps:

Firstly, you will need to drain the fuel tank. This can be done by removing the fuel filler cap and disconnecting the battery ground cable. Then, raise the vehicle on a hoist and remove the rubber cap from the drain tube at the rear of the fuel tank. Connect a portable holding tank to the drain tube and drain the fuel tank into the holding tank.

Next, you will need to remove the fuel tank. This involves removing the screws that hold the filler tube to the inner and outer quarter panel, as well as the fuel pump module electrical connector retainer. Depress the retaining tab on the rear of the electrical connector to allow the connector latch to clear the tab, and then pull the connector from the pump module. Disconnect the fuel line quick-connect fittings from the tank and use a transmission jack to support the fuel tank. Remove the bolts from the fuel tank straps and carefully lower the tank, removing the filler tube and disconnecting the pressure relief/rollover valve hose.

Now that the fuel tank is accessible, you can begin the cleaning process. Use a brush to clean the area where the pump is being removed from, and then remove the fuel pump from the tank, being careful not to let residual debris fall into the tank. Insert a hose into the fuel tank and begin pouring a stream of clean, hot water into the tank. While the water is filling, spray a mild detergent inside the tank. If the opening allows, use a brush to loosen debris from the sides of the tank. Stop the stream of water and swish the water around to capture any remaining debris. Dump the dirty water into a pan, being sure to capture any liquids. Wipe the tank with a lint-free washcloth and dry the tank completely with compressed air.

Finally, inspect the tank for any signs of rust or physical damage. If there is any damage, the tank must be repaired or replaced. Add fuel line antifreeze/water remover to the tank to absorb any residual moisture and let it sit for 30 minutes.

To install the new O-ring seal, follow these steps:

• Remove the three Phillips-head screws from the filler nozzle cap on the outside of the car.
• Remove the five Phillips-head screws from the plate on top of the fuel tank that covers the fuel tank filler tube.
• Remove the breather line on the inside of the filler tube, located inside the wing. Pull off the rubber connecting hose.
• Move the filler tube tank cover backward away from the tank.
• Rotate and pull out the filler tube.
• Carefully remove the old O-ring from the tank neck with a small screwdriver.
• Clean and inspect the tube filler neck and use a rotary wire brush and fine emery paper to smooth out any rough areas.
• Cover the new O-ring in sealer and push it into the O-ring groove.
• Cover the end of the filler tube in sealer.
• Push the tube back into the tank and O-ring.
• Refit the tube, breather, and tank cover. Ensure that the breather tube is correctly positioned on the far side of the tank cover.

Once the new O-ring seal is installed, you can reinstall the fuel tank and fuel pump, following the reverse of the removal procedure. Be sure to use a new O-ring when reinstalling the fuel pump.

Position the new fuel pump and secure with the lock-ring

Position the new fuel pump into the tank and secure it with the lock-ring. It is important to note that the fuel pump is spring-loaded, so while inserting the pump, be careful not to bend the arm. This assembly needs to be inserted in a way that the locating tab sets between the retainers on top of the tank.

Once the pump is in its place, put the locking ring back in. While compressing the spring slightly, start the locking ring and turn it clockwise with a nonferrous brass punch. Do not overtighten the lock-ring, or the fuel pump seal could split and leak.

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