How do I Change a Fuel Pump on Dodge Cars

by Contributing Writer; Updated June 12, 2017

These vehicles include coupes, vans, sedans and a compact sports car. Despite this great variety, the main difference in the process for replacing the fuel pump on these vehicles is whether or not they have a quick access panel to the pump. For the other vehicles, the fuel tank has to be dropped to reach the fuel pump. Expect this job to take an afternoon to finish.

Under The Hood:

 How do I Change a Fuel Pump on a 2005 Dodge?

2005 Dodge With a Fuel Pump Access Panel

Remove the negative battery terminal nut with the wrench. Lift off the negative cable and set it aside.

Remove the fuel pump relay from the fuse and relay box in the engine bay. Check the diagram below the cover of the box for the location of the relay.

Unscrew the small black cap on the Shraeder valve on the fuel rail in the engine bay. Press the Shraeder valve down with rags. This releases pressure from the engine. The rags collect any gas that leaks out of the valve.

Remove the rear seats to reveal the access hole to the fuel pump for the SRT-4. Remove the rear seats by pulling up on the black tabs at the front of the base of the seats. For the Stratus, open the trunk and take out the carpet to reveal the fuel pump access panel. Remove the four screws securing the panel to the trunk. Pull off the panel.

Disconnect the EVAP, return line and electrical connector on the fuel pump.

Spray the pump and area around it with compressed air to clean off any debris or particulate that could contaminate the gas tank.

Release the retaining ring by hitting the tabs with the screwdriver and hammer. Pull off the ring. Lift out the pump and pump O-ring.

Lubricate the O-ring of the new fuel pump. Set it on the gas tank opening. Insert the fuel pump. Secure it there with the retaining ring.

Attach the EVAP, fuel return line and electrical connector to the new fuel pump.

Reconnect the battery cable and fuel pump relay. Prime the fuel system by turning on the ignition several times until the engine cranks. Check for gas leaks. Retighten any leaky fittings.

2005 Dodge Without a Fuel Pump Access Panel

Complete Steps 1 through 3 of Section 1. Siphon out all of the gas from the Dodge's tank with the siphon kit and spare gas cans.

Turn on the emergency parking brake. Raise the Dodge with the car jack. Set two jack stands below the Dodge to increase stability while you work underneath the vehicle.

Disconnect the fuel filler line from the gas tank. Disconnect the vent line from the tank. Set the floor jack below the tank. Remove a strap holding the tank in place. Drop the loosened end of the tank onto the floor jack. Reach above the tank. Disconnect the EVAP line, return fuel line and electrical connector from the fuel pump. Loosen the second strap. Drop the tank onto the floor jack. Push the floor jack out from below the Dodge.

Complete Steps 6 through 8 of Section 1.

Reinstall the fuel tank below your Dodge. Connect the hoses and electrical connector to the fuel pump. Reconnect the filler and vent lines to the gas tank. Refill the tank. Replace the battery cable and relay. Prime the fuel system. Check for gas leaks. Lower the Dodge.

Items you will need

  • Socket wrench set

  • Rags

  • Screwdrivers

  • Latex gloves

  • Compressed air canister

  • Hammer

  • Motor oil

  • Replacement fuel pump

  • Siphon pump kit

  • Gas cans

  • Car jack

  • Jack stands

  • Floor jack

 How Do I Change the Fuel Pump on an Intrepid?

Relieve the fuel pressure system. Remove the gas filler cap and start the engine. Let the engine idle while removing the fuel pump relay or fuse from the fuse box. Wait a few seconds until the engine stalls, then crank the engine for about 3 seconds to relieve the remaining pressure from the system.

Remove the rear seat from the vehicle, unplug the fuel pump assembly electrical connector located under the seat and disconnect the black (negative) battery cable.

Raise the rear of the vehicle using a floor jack and support it safely on jack stands.

Place a catch pan under the fuel tank and remove the drain plug from the tank using a wrench or ratchet and socket to empty the tank. Reinstall the drain plug.

Disconnect the stabilizer bar brackets from the vehicle body and move the bar out of the way towards the rear of the car.

Set the floor jack underneath the fuel tank to support it as you get ready to lower the tank.

Disconnect the tank supporting straps starting at the passenger side. Lower the tank and disconnect the purge and vent lines.

Disconnect the fuel line from the pump assembly by pressing the quick connector on the pump module. Push in the connector and then pull the line away to disengage the line. Slide the fuel pump module electrical connector lock to unlock it; push the connector retainer down and then pull it from the module to disconnect it.

Remove the lock nut from the fuel pump module using special tool #6856, which you can buy from the dealer. Lift the pump module off the tank and remove the O-ring seal from the tank. Install the new fuel pump in the module assembly.

Clean the fuel pump module mounting area and place a new O-ring fuel pump seal. Set the fuel module in the tank and align the module flange tabs with the notches on the fuel tank. Tighten the lock nut, being careful not to over tighten the lock.

Connect the fuel pump electrical connector, purge, vent and fuel lines. Raise the fuel tank slightly with the jack, if necessary, to connect all the lines, then raised the tank to its mounting position and reconnect the tank straps, filler tube and stabilizer bar.

Lower the car and plug the electrical connect located underneath the rear seat. Install the rear seat, fuel pump relay and negative battery cable. Refill the tank, start the engine and check for leaks.

Items you will need

  • Floor jack and 2 jack stands Catch pan Wrench set Ratchet and socket set Dodge tool #6856 New O-ring fuel tank seal

 How to Change a Fuel Pump in a Dodge Ram

Removing the Fuel Tank

Relieve the pressure in the fuel system--remove the filler cap to relieve pressure in the tank, then remove the fuel pump relay in the fuse box. Crank the engine for several seconds and look for it to stall after running for a few seconds or not start at all. Disconnect the negative battery cable.

Raise the rear end of the truck and support it on jack stands. If you have a four-door Ram with a six-foot bed, remove the left rear wheel.

Disconnect the hoses from the metal pipes on the fuel and EVAP lines by loosening their clamps with a flat-blade screwdriver.

Support the tank by raising a transmission jack or floor jack underneath it. If you use a floor jack, place a block of wood on the jack head to protect the tank.

Unstrap the tank from the vehicle by removing the nuts on the straps with a wrench. Lower the jack until the tank is low enough for you to disconnect the electrical connector and the fuel supply line from the fuel pump module. Disconnect these and remove the tank.

Changing the Pump Unit

Clean the surface of the fuel tank with acetone or lacquer thinner, especially around the pump module, to prevent contaminants from entering the tank.

Disconnect the fuel line from the fuel filter and pressure regulator by depressing the quick-connect fitting tabs. Unplug the electrical connector by pushing the lock toward the fuel line fitting and depressing the release button.

Turn the lock ring on the fuel pump module with a large pair of pliers. You can also tap on the lock ring with a hammer and drift, turning it clockwise. Unscrew the ring once it is loose.

Lift the fuel pump module carefully out of the tank. Check the condition of the rubber gasket on the mounting hole and replace it if it is cracked, torn or damaged in any way.

Install the new fuel pump module within the tank, rotating it so the alignment arrow on the module lines up with the middle of the three hash marks on the top of the tank. (The fuel pipe on the filter/pressure regulator must also point toward the driver's side of the truck.)

Re-attach the lock ring on the module, using the pliers or the hammer and drift to tighten it.

Re-connect the fuel tank onto the truck and connect all the lines to the tank in the reverse order of removal. Replace the wheel if you removed it, and lower the truck once the tank is secure.

Connect the negative battery cable and the fuel pump relay. Turn the ignition switch to the "On" position for two seconds. Turn it back off for five seconds. Repeat several times. (This will re-pressurize the fuel system.)

Items you will need

  • Jack

  • Jack stands

  • Lug wrench

  • Flat blade screwdriver

  • Acetone/lacquer thinner

  • Large pliers

  • Hammer and drift (optional)

  • Fuel pump module

 How to Replace a Fuel Pump in a Dodge Caravan

Determine which fuel pump your Dodge Caravan will need. This depends not only on the make and model, but also the engine size. Models for 2001 to 2007 may have a 2.4 L EDZ, 3.3 L EGA or 3.8 L EGH engine. Models after 2007 have a 3.3 L EGA, 3.8 L EGH or 4.0 L engine.

Prepare your vehicle for fuel pump servicing. Relieve the fuel system pressure and drain the fuel tank. Disconnect the negative battery cable with a socket wrench. Support the fuel tank and loosen the strap bolts.

Disconnect the fuel lines from the fuel tank and disconnect the fuel pump's electrical connector.

Access the fuel pump by lowering the fuel tank. Remove the locking ring on the fuel pump with a socket wrench and remove the fuel pump.

Install the new fuel pump using the items included in the kit and tighten the locking ring to 40 foot lbs with a torque wrench. You will also need a torque wrench to tighten the main straps on the fuel tank to 40 foot lbs. and the T strap to 250 inch lbs.

Items you will need

  • Fuel pump kit

  • Socket wrench set

  • Torque wrench

 How to Replace the Fuel Pump on a 2003 Dodge Ram

Disconnect the fuel vent hose from the fuel vent fitting located on the outer portion of the left frame rail. Attach one end of hose no. 6541, 6539, 6631 or 6923 to this fuel vent fitting. The correct hose depends on the specific model and engine of your vehicle. Siphon the fuel from the fuel system into a gasoline container. Connect the fuel vent hose to the fuel vent fitting.

Remove the filler tube cap for the fuel tank. Raise and support the vehicle on jack stands. Disconnect the cable from the negative battery terminal with a socket wrench.

Disconnect the electrical wiring harness and fuel lines from the fuel pump module. Remove the fuel tank. Turn the locknut on the fuel pump module counter-clockwise with special tool 6856, and remove the locknut. Remove the fuel pump module from the fuel tank.

Install the new fuel pump module onto the fuel tank. Place the locknut into position and turn it clockwise with special tool 6856 until it locks into place. Install the fuel tank, and connect the wiring harness and fuel lines to the fuel pump module.

Connect the cable for the negative battery terminal with a socket wrench. Lower the vehicle and replace the filler tube cap for the fuel tank. Start the engine and inspect the fuel system for leaks.

Items you will need

  • Hose no. 6541, 6539, 6631 or 6923

  • Gasoline container

  • Jack stands

  • Socket wrench set

  • Special tool 6856

 How to Replace a Fuel Pump in a Dodge Ram

Select the new fuel pump for your Dodge Ram. You will not only need to know the make and model, but also the engine size. Models made before 1994 will have a 225 cubic inch (ci), 239 ci, 318 ci or 360 ci gasoline-powered engine or a 5.9 L diesel engine. Models made from 1994 to 2001 will have a 3.9 L, 5.2 L, 5.9 L (gasoline or diesel) or 8.0 L engine.

Look at engines for recent models of the Dodge Ram. Models made after 2001 may be equipped with a 3.7 L, 4.7 L, 5.7 L Hemi V8, 5.9 L Magnum V8, 5.9 L Cummins diesel, 6.7 L Cummins diesel, 8.0 L Magnum or 8.3 L Viper engine.

Prepare your vehicle for fuel pump servicing. Relieve the fuel system pressure and disconnect the negative battery cable with a socket wrench. Drain and disconnect the fuel tank.

Remove the fuel pump's electrical connector and disconnect the fuel line from the fuel tank. You may now remove the fuel tank. Remove the locknut for the fuel pump with tool 6856 by turning it counterclockwise and disconnect the fuel pump. Discard the old O-ring.

Install the new fuel pump using the items included in the kit, especially the O-ring. Ensure that the alignment tab under the fuel pump sits in the notch on the fuel tank. Tighten the locking ring to 40 in. lbs. with tool 6856.

Complete the installation by reversing the removal procedure.

Items you will need

  • Fuel pump kit

  • Socket wrench set

  • Tool 6856

 How to Replace a Fuel Pump in a Dodge Intrepid

Determine the fuel pump that your Dodge Intrepid will require. This depends on the make and model and engine size of your vehicle. Models made from 1993 to 1997 have a 3.3 L EGA or 3.5 L EGJ engine. Models produced after 1997 are equipped with a 2.7 L EER, 3.2 L or 3.5 L EGJ engine.

Relieve the fuel system pressure. Disconnect the negative battery cable with a socket wrench and remove the fuel tank.

Remove any loose dirt from the top of the tank and remove the fuel lines from the fuel pump by squeezing the quick-connect fittings. Disconnect the electrical connector for the fuel pump and use tool 6856 to remove the lock nut for the fuel pump by turning it counterclockwise. Remove the fuel pump and discard the O-ring from the fuel tank.

Install the new fuel pump using the items included in the kit, especially the O-ring. Ensure that the alignment tab under the fuel pump sits in the notch on the fuel tank. Use tool 6856 to torque the locking ring to 40 inch lbs.

Complete the installation by reversing the removal procedure.

Items you will need

  • Fuel pump kit

  • Socket wrench set

  • Tool 6856

About the Author

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