Dodge Durango (DN). Manual — part 11

The o-rings and spacer will remain in quick-con-
nect fitting connector body.
(6)

Plastic Retainer Ring Type Fitting: This

type of fitting can be identified by the use of a full-
round plastic retainer ring (Fig. 17) usually black in
color.

(a) To release fuel system component from quick-

connect fitting, firmly push fitting towards compo-
nent being serviced while firmly pushing plastic
retainer ring into fitting (Fig. 17). With plastic ring
depressed, pull fitting from component. The plas-
tic retainer ring must be pressed squarely
into fitting body. If this retainer is cocked
during removal, it may be difficult to discon-

nect fitting. Use an open-end wrench on
shoulder of plastic retainer ring to aid in dis-
connection.

Fig. 14 Disconnecting Single-Tab Type Fitting

1 – PULL TAB
2 – SCREWDRIVER
3 – QUICK-CONNECT FITTING

Fig. 15 Removing Pull Tab

1 – FUEL TUBE OR FUEL SYSTEM COMPONENT
2 – PULL TAB
3 – QUICK-CONNECT FITTING
4 – FUEL TUBE STOP

Fig. 16 Typical Two-Tab Type Quick-Connect Fitting

1 – TAB(S)
2 – QUICK-CONNECT FITTING

Fig. 17 Plastic Retainer Ring Type Fitting

1 – FUEL TUBE
2 – QUICK CONNECT FITTING
3 – PUSH
4 – PLASTIC RETAINER
5 – PUSH
6 – PUSH
7 – PUSH
8 – PUSH

14 - 12

FUEL SYSTEM

DN

SERVICE PROCEDURES (Continued)

(b) After disconnection, plastic retainer ring will

remain with quick-connect fitting connector body.

(c) Inspect fitting connector body, plastic retainer

ring and fuel system component for damage.
Replace as necessary.
(7) Latch Clips: Depending on vehicle model and

engine, 2 different types of safety latch clips are used
(Fig. 18) or (Fig. 19). Type-1 is tethered to fuel line
and type-2 is not. A special tool will be necessary to

disconnect fuel line after latch clip is removed. The
latch clip may be used on certain fuel line/fuel rail
connection, or to join fuel lines together.

(a) Type 1: Pry up on latch clip with a screw-

driver (Fig. 18).

(b) Type 2: Separate and unlatch 2 small arms

on end of clip (Fig. 19) and swing away from fuel
line.

(c) Slide latch clip toward fuel rail while lifting

with screwdriver.

(d) Insert special fuel line removal tool (Snap-On

number FIH 9055-1 or equivalent) into fuel line
(Fig. 20). Use tool to release locking fingers in end
of line.

(e) With special tool still inserted, pull fuel line

from fuel rail.

(f) After

disconnection,

locking

fingers

will

remain within quick-connect fitting at end of fuel
line.
(8) Disconnect quick-connect fitting from fuel sys-

tem component being serviced.

CONNECTING

(1) Inspect quick-connect fitting body and fuel sys-

tem component for damage. Replace as necessary.

(2) Prior to connecting quick-connect fitting to

component being serviced, check condition of fitting
and component. Clean parts with a lint-free cloth.
Lubricate with clean engine oil.

(3) Insert quick-connect fitting into fuel tube or

fuel system component until built-on stop on fuel
tube or component rests against back of fitting.

(4) Continue pushing until a click is felt.
(5) Single-tab type fitting: Push new tab down

until it locks into place in quick-connect fitting.

Fig. 18 Latch Clip—Type 1

1 – TETHER STRAP
2 – FUEL LINE
3 – SCREWDRIVER
4 – LATCH CLIP
5 – FUEL RAIL

Fig. 19 Latch Clip—Type 2

1 – LATCH CLIP

Fig. 20 Fuel Line Disconnection Using Special Tool

1 – SPECIAL FUEL LINE TOOL
2 – FUEL LINE
3 – FUEL RAIL

DN

FUEL SYSTEM

14 - 13

SERVICE PROCEDURES (Continued)

(6) Verify a locked condition by firmly pulling on

fuel tube and fitting (15-30 lbs.).

(7) Latch Clip Equipped: Install latch clip (snaps

into position). If latch clip will not fit, this indi-
cates fuel line is not properly installed to fuel
rail (or other fuel line). Recheck fuel line con-
nection.

(8) Connect negative cable to battery.
(9) Start engine and check for leaks.

REMOVAL AND INSTALLATION

FUEL FILTER/FUEL PRESSURE REGULATOR

REMOVAL

WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT

PRESSURE,

EVEN

WITH

ENGINE

OFF.

BEFORE

SERVICING

THE

FUEL

FILTER/FUEL

PRESSURE

REGULATOR,

THE

FUEL

SYSTEM

PRESSURE MUST BE RELEASED.

Refer to Fuel System Pressure Release in the Fuel

Delivery System section of this group.

The fuel filter/fuel pressure regulator is located at

top of fuel pump module on top of fuel tank (Fig. 22).

Fuel pump module removal is not necessary for fil-

ter/regulator removal.

(1) Drain fuel tank and remove tank. Refer to Fuel

Tank Removal/Installation.

(2) Clean area around filter/regulator to prevent

contaminants from entering pump module.

(3) The fuel filter/regulator is pressed into a rub-

ber

grommet.

Remove

by

twisting

and

pulling

straight up.

CAUTION:

Do not pull filter/regulator more than

three inches from fuel pump module. Damage to
coiled fuel tube (line) may result.

(4) Gently cut old fuel tube (line) clamp (Fig. 23)

taking care not to damage plastic fuel tube. Remove
and discard old fuel tube clamp.

(5) Remove plastic fuel tube from filter/regulator

by gently pulling downward. Remove filter/regulator
from fuel pump module.

INSTALLATION

(1) Install a new clamp over plastic fuel tube.
(2) Install filter/regulator to fuel tube. Rotate fil-

ter/regulator in fuel tube (line) (Fig. 24) until it is
pointed towards front of tank (or front of vehicle).

(3) Tighten line clamp to fuel line using special

Hose Clamp Pliers number C-4124 or equivalent
(Fig. 24). Do not use conventional side cutters to
tighten this type of clamp.

(4) Press filter/regulator (by hand) into rubber

grommet.

(5) Rotate filter/regulator until pointed towards

front of vehicle (Fig. 22).

(6) Install fuel tank. Refer to Fuel Tank Removal/

Installation.

(7) Check for fuel leaks.

Fig. 21 Fuel Filter/Fuel Pressure Regulator

1 – INTERNAL FUEL FILTER
2 – FUEL FLOW TO FUEL INJECTORS
3 – FUEL FILTER/FUEL PRESSURE REGULATOR
4 – EXCESS FUEL BACK TO TANK
5 – FUEL INLET
6 – RUBBER GROMMET
7 – TOP OF PUMP MODULE

Fig. 22 Filter/Regulator Location

1 – FUEL PUMP MODULE
2 – FRONT ROLLOVER VALVE
3 – FUEL FILTER/FUEL PRESSURE REGULATOR
4 – FUEL TANK
5 – EVAP LINE
6 – REAR ROLLOVER VALVE

14 - 14

FUEL SYSTEM

DN

SERVICE PROCEDURES (Continued)

FUEL PUMP MODULE

REMOVAL

WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH ENGINE OFF).
BEFORE SERVICING FUEL PUMP MODULE, FUEL
SYSTEM PRESSURE MUST BE RELEASED.

The fuel pump module is located in top of fuel

tank.

(1) Drain fuel tank and remove tank. Refer to Fuel

Tank Removal/Installation in this group.

(2) Thoroughly wash and clean area around pump

module to prevent contaminants from entering tank.

(3) Part of Fuel Tank Removal Procedure: Discon-

nect EVAP line at pump module (Fig. 25); disconnect
wiring harness connector at pump module; disconnect
fuel line from fuel filter fitting.

(4) Rotate fuel filter until its fitting is pointed

towards center of pump module.

(5) A metal lockring is used to secure fuel pump

module to fuel tank (Fig. 25). Six metal fingers (Fig.
25) are molded into the plastic fuel tank. The fingers
are used to retain lockring to fuel tank. A rubber gas-
ket is used as a seal between module and fuel tank.

(6) Before

removing

lockring,

apply

a

small

amount of engine oil to 6 fingers where fingers meet
lockring (to act as a lubricant).

(7) Remove

(rotate)

lockring

counterclockwise

using a brass or bronze drift punch and a hammer.
This must be done while slightly prying back on lock
tab (Fig. 25).

(8) Remove lockring and pump module from fuel

tank.

INSTALLATION

CAUTION: Whenever fuel pump module is serviced,
the module gasket must be replaced.

Fig. 23 Fuel Tube and Clamp—TYPICAL

1 – FUEL FILTER/FUEL PRESSURE REGULATOR
2 – TUBE CLAMP
3 – FUEL TUBE
4 – RUBBER GROMMET
5 – TOP OF PUMP MODULE

Fig. 24 Tightening Fuel Filter Tube Clamp—TYPICAL

1 – TOOL C-4124
2 – TUBE CLAMP
3 – TOP OF PUMP MODULE
4 – FUEL TUBE

Fig. 25 Fuel Pump Module and Lockring

1 – FINGER LOCK (6)
2 – LOCK TAB
3 – ELEC. CONNEC.
4 – LOCKRING
5 – EVAP LINE
6 – FUEL PUMP MODULE
7 – FINGERS (6)

DN

FUEL SYSTEM

14 - 15

REMOVAL AND INSTALLATION (Continued)