How to Install a Fuel Pump on a 2004 Dodge Neonby Don Bowman
The 2004 Dodge Neon's fuel pump and filter, which strains the fuel of debris, along with the fuel level indicator and sensor are located inside the fuel tank. One complete module contains all these components. The fuel tank must be lowered in order to access the fuel pump module. Removing the fuel pump is not a difficult process, however the appropriate cautions should be adhered to when working around an open tank of fuel. Fuel vapors are extremely flammable. Bystanders must maintain their distance and no smoking allowed within 50 feet of the vehicle.
Block the front wheels to prevent rolling. Raise the rear of the Neon with the jack under the rear axle. Place jack stands under both sides of the car just forward of the rear wheels. This will keep them out of the way when dropping the fuel tank. Disconnect the fuel pump harness connector in the rear of the tank.
Loosen the clamps on the fuel filler and vent hose with a screwdriver on the driver’s side of the fuel tank. Place the floor jack under the center of the fuel tank and raise it just enough to touch the tank.
Remove the two bolts in the retaining straps between the fuel tank and rear bumper using a socket. Lower the straps. Lower the fuel tank slowly until the top of the fuel tank can be accessed. Remove the fuel and vent lines by depressing the fittings and pulling them off. Lower the tank to the ground.
Remove the fuel pump retaining cover, which is a round cap that unscrews counterclockwise. If you encounter difficulty in getting it to turn, use a screwdriver positioned on the cap flange and a hammer to tap the screwdriver on the end to loosen the cap enough so that you can remove it. Lift the fuel pump out of the fuel tank taking care not to damage the fuel sending unit float arm.
Remove the fuel level sensor in the bottom of the pump module. Pull the wedge clip out. Disconnect the two wires and push the sensor out of its slot with a screwdriver.
Install the fuel level sensor and plug in the two wires. Push the sensor itself into its slot until it snaps in place. Install the safety wedge by pushing it under the sensor. Install the new O-ring on the lip of the tank opening. Install the fuel pump module orientating the fuel connector connections properly.
Install the fuel pump module cap and rotate it clockwise to tighten it. Place the fuel tank on the jack and raise it enough to engage the fuel lines by pushing them on until they snap in place. Continue raising the tank until the filler and vent hose can be installed. Tighten the clamps with the screwdriver.
Raise the tank until it touches the undercarriage of the vehicle. Install the support straps and tighten the two support bolts with a socket. Connect the fuel pump harness connector. Lower the car to the ground.
- Use extreme caution when working with a fuel tank. To make the process easier, drain the tank of as much fuel as possible beforehand. Transfer the fuel with a pump into an approved container for holding gasoline.
Things You'll Need
- Floor jack
- Jack stands
- Set of sockets
- Common screwdriver
- Gasonline is probably the worst feeling a person can have in their eyes. Its not deadly, but you don't want to do it. Wear googles for this one!
- Gas is flamable! Don't smoke or play with matches while doing this job
Don Bowman has been writing for various websites and several online magazines since 2008. He has owned an auto service facility since 1982 and has over 45 years of technical experience as a master ASE tech. Bowman has a business degree from Pennsylvania State University and was an officer in the U.S. Army (aircraft maintenance officer, pilot, six Air Medal awards, two tours Vietnam).