Dodge Neon / Neon SRT-4. Manual — part 281

(2) Pull off blue locking wedge (Fig. 5).

(3) Using a small screwdriver lift locking finger

away from terminal and push terminal out of connec-
tor (Fig. 6).

(4) Push level sensor signal and ground terminals

out of the connector (Fig. 6).

(5) Slide level sensor wires through opening fuel

pump module (Fig. 7).

(6) Slide level sensor out of installation channel in

module.

INSTALLATION

(1) Insert level sensor wires into bottom of opening

in module.

(2) Wrap wires into groove in back of level sensor.
(3) While feeding wires into guide grooves, slide

level sensor up into channel until it snaps into place
(Fig. 7). Ensure tab at bottom of sensor locks in
place.

(4) Install level sensor wires in connector. Push

the wires up through the connector and then pull
them down until they lock in place. Ensure signal

and ground wires are installed in the correct posi-
tion.

(5) Install locking wedge on connector.
(6) Push connector up into bottom of fuel pump

module electrical connector.

(7) Install fuel pump module. Refer to Fuel Pump

Module in this section.

FUEL LINES

DESCRIPTION - FUEL LINES/HOSES AND
CLAMPS

Also refer to Quick-Connect Fittings.

WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRES-
SURE MUST BE RELEASED. REFER TO THE FUEL
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP. THIS MAY RESULT IN PERSONAL
INJURY OR DEATH.

The lines/tubes/hoses used on fuel injected vehicles

are of a special construction. This is due to the
higher fuel pressures and the possibility of contami-
nated fuel in this system. If it is necessary to replace
these lines/tubes/hoses, use new original equipment
lines/tubes/hoses.

If equipped: The hose clamps used to secure rub-

ber hoses on vehicles are of a special rolled edge con-
struction. This construction is used to prevent the
edge of the clamp from cutting into the hose. Only
these rolled edge type clamps may be used in this

Fig. 5 Wire Terminal Locking Wedge

1 - ELECTRICAL CONNECTOR
2 - BLUE LOCKING WEDGE

Fig. 6 Removing Wires From Connector

1 - LOCKING FINGER
2 - WIRE TERMINAL

Fig. 7 Level Sensor

1 - REAR VIEW OF LEVEL SENSOR
2 - LEVEL SENSOR
3 - WRAP WIRES IN GROOVE
4 - CHANNEL FOR LEVEL SENSOR

14 - 6

FUEL DELIVERY

PL/SRT-4

FUEL LEVEL SENDING UNIT / SENSOR (Continued)

system. All other types of clamps may cut into the
hoses and cause leaks.

Use new original equipment type hose clamps.

STANDARD PROCEDURE - HOSES AND CLAMP

Inspect all hose connections (clamps and quick con-

nect fittings) for completeness and leaks. Replace
cracked, scuffed, or swelled hoses. Replace hoses that
rub against other vehicle components or show sign of
wear.

Fuel injected vehicles use specially constructed

hoses. When replacing hoses, only use hoses marked
EFM/EFI.

When installing hoses, ensure that they are routed

away from contact with other vehicle components
that could rub against them and cause failure. Avoid
contact with clamps or other components that cause
abrasions or scuffing. Ensure that rubber hoses are
properly routed and avoid heat sources.

The hose clamps have rolled edges to prevent the

clamp from cutting into the hose. Only use clamps
that are original equipment or equivalent. Other
types of clamps may cut into the hoses and cause
high pressure fuel leaks. Tighten hose clamps to 1
N·m (9 in. lbs.) torque.

Inspect all hose connections such as clamps, cou-

plings and fittings to make sure they are secure and
leaks are not present. The component should be
replaced immediately if there is any evidence of deg-
radation that could result in failure.

Never attempt to repair a plastic fuel line/tube.

Replace as necessary.

Avoid contact of any fuel tubes/hoses with other

vehicle components that could cause abrasions or
scuffing. Be sure that the plastic fuel lines/tubes are
properly routed to prevent pinching and to avoid heat
sources.

FUEL PRESSURE REGULATOR

DESCRIPTION

A combination fuel filter and fuel pressure regula-

tor is used on all gas powered engines. It is located
on the top of the fuel pump module.

It contains a diaphragm, calibrated springs and a

fuel return valve. The internal fuel filter (Fig. 8) is
also part of the assembly.

OPERATION

Fuel Pressure Regulator Operation: The pres-

sure regulator is a mechanical device that is cali-
brated to maintain fuel system operating pressure of
approximately 400 kPa ±34 kPa (58 psi ±5 psi.) at
the fuel injectors.

Fuel is supplied to the filter/regulator by the elec-

tric fuel pump through an opening tube at the bot-
tom of filter/regulator (Fig. 8).

The fuel pump module contains a check valve to

maintain some fuel pressure when the engine is not
operating. This will help to start the engine.

If fuel pressure at the pressure regulator exceeds

approximately 58 psi, an internal diaphragm closes
and excess fuel pressure is routed back into the tank
through the pressure regulator. A separate fuel
return line is not used with any gas powered engine.

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.

(1) Refer to Fuel System Pressure Release in the

Fuel Delivery System section of this group. The fuel
filter/fuel pressure regulator is located on the top of
fuel pump module. Fuel pump module removal is not
necessary.

(2) Raise vehicle on hoist.

Fig. 8 Side View—Filter/Regulator

1 - INTERNAL FUEL FILTER
2 - FUEL FLOW TO FUEL INJECTORS
3 - FUEL FILTER/FUEL PRESSURE REGULATOR
4 - O-RINGS
5 - EXCESS FUEL BACK TO TANK
6 - FUEL INLET
7 - CALIBRATED SPRINGS
8 - RUBBER GROMMET AT PUMP MODULE
9 - LOCKING TAB

PL/SRT-4

FUEL DELIVERY

14 - 7

FUEL LINES (Continued)

(3) Disconnect fuel supply line at the Filter/Regu-

lator nipple (refer to Quick Connect Fittings in this
section).

(4) Depress locking spring tab on side of Fuel/Reg-

ulator (Fig. 9) and rotate 90° counter-clockwise and
pull out.

NOTE: Make sure that the upper and lower O-rings
are on the Filter/Regulator assembly.

INSTALLATION

Lightly lubricate the O-rings with engine oil.
(1)

Insert Filter/Regulator into the opening in the

fuel pump module, align the two hold down tabs with
the flange.

(2) While applying downward pressure, rotate the

Filter/Regulator clockwise until the the spring tab
engages the locating slot (Fig. 10).

(3) Connect the fuel line to the Filter/Regulator.
(4) Lower vehicle from hoist.

FUEL PUMP

DESCRIPTION

The electric fuel pump is located in and is part of

the fuel pump module. It is a positive displacement,
gerotor type, immersible pump with a permanent
magnet electric motor. The fuel pump module is sus-
pended in fuel in the fuel tank.

OPERATION

The pump draws fuel through a strainer and

pushes it through the motor to the outlet. The pump
contains a check valve. The valve, in the pump out-
let, maintains pump pressure during engine off con-

ditions, for a short while. It is normal for fuel
pressure to drop to zero after cooldown. The fuel
pump relay provides voltage to the fuel pump. The
fuel pump has a maximum deadheaded pressure out-
put of approximately 880 kPa (130 psi). The regula-
tor adjusts fuel system pressure to approximately
400 kpa ±34 kpa (58 psi ± 5 psi).

FUEL PUMP MODULE

DESCRIPTION

The fuel pump module is installed in the fuel tank

(Fig. 11).

Fig. 9 Locking Spring Tab

1 - FUEL FILTER/PRESSURE REGULATOR
2 - SPRING TAB
3 - LOCATING SLOT

Fig. 10 Spring Tab In Locating Slot

1 - FUEL FILTER/PRESSURE REGULATOR
2 - SPRING TAB
3 - LOCATING SLOT

Fig. 11 Fuel Pump Module

1 - FUEL FILTER/PRESSURE REGULATOR
2 - FUEL LEVEL SENSOR
3 - FUEL RESERVOIR
4 - INLET STRAINER
5 - FLOAT

14 - 8

FUEL DELIVERY

PL/SRT-4

FUEL PRESSURE REGULATOR (Continued)

OPERATION

The fuel pump module contains the following:
• Electric fuel pump

• Fuel pump reservoir

• Inlet strainer

• Fuel filter/pressure regulator

• Fuel gauge sending unit

• Fuel supply line connection
The inlet strainer, fuel pressure regulator and fuel

level sensor are the only serviceable items. If the fuel
pump requires service, replace the fuel pump module.

REMOVAL

WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE.

(1) Drain the fuel. Refer to Draining Fuel Tank in

the Fuel Tank section of this group.

WARNING: THE FUEL RESERVOIR OF THE FUEL
PUMP MODULE DOES NOT EMPTY OUT WHEN THE
TANK IS DRAINED. THE FUEL IN THE RESERVOIR
WILL

SPILL

OUT

WHEN

THE

MODULE

IS

REMOVED.

(2) Remove fuel tank, refer to the Fuel Tank

removal/installation section.

(3) Lower tank (Fig. 12).
(4) Use Special Tool 6856 to remove fuel pump

module locknut (Fig. 13).

(5) Remove fuel pump and O-ring seal from tank.

Discard old seal.

INSTALLATION

(1) Wipe seal area of tank clean and place a new

seal in position in the tank opening.

(2) Position fuel pump in the tank. Make sure the

alignment tab on the underside of the fuel pump
module flange sits in the notch on the fuel tank (Fig.
14).

(3) Position the locknut over the fuel pump mod-

ule.

(4) Tighten the locknut using Special Tool 6856 to

55 N·m (40.5 ft. lbs.) (Fig. 13).

CAUTION: Over tightening the pump lock ring may
result in a leak.

(5) Install fuel tank, refer to the Fuel Tank remov-

al/installation section.

Fig. 12 Fuel Pump Module

1 - FUEL FILTER/PRESSURE REGULATOR
2 - FUEL LINE
3 - LOCKNUT

Fig. 13 Fuel Tank

1 - SPECIAL TOOL 6856
2 - LOCKNUT

Fig. 14 Alignment Tab

PL/SRT-4

FUEL DELIVERY

14 - 9

FUEL PUMP MODULE (Continued)