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In order to replace the fuel pump on a dodge ram follow the instructions below
The fuel pump on this vehicle is electric so check all fuses and relays to ensure this isnt whats causing you the problem as it is quite a big job to change the fuel pump.
1. Make sure you purchase the correct fuel pump as their are different size and shapes depending on ago of vehicle, model of vehicle and engine size the type of pump will vary so make sure you buy correct type.
2. you now need to relieve the fuel system of pressure you can do this by removing the pipe that goes to the injectors put a bit of rag over it to stop it spraying any where, their wont be loads come out its just pressurized. Also undo the negative lead from the battery.
3. you now need to drain and disconnect the fuel tank ie undo the pipes coming from the tank be careful of the filler hose this will also need undoing. Remove the fuel pumps electrical connector and remove the fuel lines connected to the tank. You should now be able to remove the tank
4. You can now get to the fuel pump, you need to remove the lock nut holding the fuel pump in place turning the nut anti clockwise. Discard the o-ring between the pump and the tank.
5. Now your ready to fit the new pump, fit the pump using everything in the kit and make sure you use the new o-ring. You must make sure that the allignment tab that sits under the fuel pump fits correctly into the notch cut into the tank.
6. Tighten the locking nut to 40in lbs.
The refit everything in reverse order. When your ready to start the engine it may take a few turns for the air to come out of the system, if needed you could leave the fuel pipe off the injectors and switch the ignition on making sure the pipe is in a bottle so you done get fuel every where, once you have fuel coming out refit the injector pipe and now you should have no problems starting the engine.
You are doing this work at your own risk, its not the easiest of jobs to do and is time consuming on a scale of 1 to 10 with 10 being the hardest i would say the job is about 3.
If you are unsure what you are doing or dont have the correct tools then leave it to an expert.
PLEASE MAKE SURE YOU RE-FIT THE INJECTOR PIPE IF YOU DID UNDO IT AS YOU COULD CAUSE A FIRE IF THIS PIPE IS LEFT OFF AS YOU WOULD HAVE FUEL COMING OUT OF THIS PIPE AND IF YOUR ENGINE SPARKS OR SHORTS YOU COULD SET FIRE TO YOUR VEHICLE.
Make sure the tank is empty as it can be really heavy if the tanks has fuel in.
The fuel lins is normally just an interference fit in the fuel tank, so diss connect the pipe from the carb, use a pair of long nose pliers through the open filler cap hole, grab the end of the pipe and pull down and out, the pipe should come away with the fuel filter attached to the end, take a new fuel hose, cut the top off at a steep angle leaving a pointed end approx 1/2" long, push this end into the top of the fuel tank, use the pliers again through the filler hole to grab the pointed end as it protrudes through the tank and pull it on through, once through pull it out through the filler hole and connect the fuel filter, there should be enough fuel hose pulled through so as the filter can freely move to all sides of the tank.
Yes, the pump is inside the tank. Good luck!
Removal & Installation
Disconnect the negative battery cable and relieve the fuel system pressure.
Siphon or pump as much fuel as possible out through the fuel filler pipe.
NOTE
All vehicles have reservoirs inside the fuel tank to maintain fuel near the fuel pickup during cornering and under low fuel operating conditions. These reservoirs could block siphon tubes or hoses from reaching the bottom of the fuel tank. Repeated attempts using different hose orientations can overcome this obstacle.
Raise and safely support the vehicle.
Remove the exhaust pipe and exhaust shield, if equipped. Disconnect the fuel fill and vent hoses connecting the filler pipe to the tank. Disconnect one end of the vapor crossover hose at the rear over the driveshaft.
If equipped with a metal retainer that fastens the filler pipe to the fuel tank, remove the screw attaching the retainer to the fuel tank flange.
Disconnect the fuel lines and the electrical connector to the fuel tank sending unit. On some vehicles, these are inaccessible on top of the tank. In these cases they must be disconnected with the tank partially removed.
Place a safety support under the fuel tank and remove the bolts from the fuel tank straps. Allow the straps to swing out of the way. Be careful not to deform the fuel tank.
Partially remove the tank and disconnect the fuel lines and electrical connector from the sending unit, if required.
Remove the tank from the vehicle.
To install:
Raise the fuel tank into position in the vehicle. Connect the fuel lines and sending unit electrical connector if it is necessary to connect them before the tank is in the final installed position.
Lubricate the fuel filler pipe with water base tire mounting lubricant and install the tank onto the filler pipe, then bring the tank into final position. Be careful not to deform the tank.
Bring the fuel tank straps around the tank and start the retaining nut or bolt. Align the tank with the straps. If equipped, make sure the fuel tank shields are installed with the straps and are positioned correctly on the tank. Align the tank with the driveshaft.
Check the hoses and wiring mounted on the tank top to make sure they are correctly routed and will not be pinched between the tank and body. Make sure the fuel vent hose is positioned above the vent retainer and not contacting the driveshaft.
Tighten the fuel tank strap retaining nuts or bolts to 22-30 ft. lbs. (29-41 Nm).
If not already connected, connect the fuel hoses and lines which were disconnected. Make sure the fuel supply, fuel return, if present, and vapor vent connections are made correctly. If not already connected, connect the sending unit electrical connector.
Install the exhaust pipe shield, if equipped, and exhaust pipe.
Lower the vehicle. Replace the fuel that was drained from the tank. Check all connections for leaks.
Drain the fuel from the tank into an approved container.
Loosen the fuel hose clamp and disconnect the hose from the fuel tank.
Disconnect the evaporative emission (EVAP) vent valve and fuel tank pressure sensor connectors.
Evaporative emission cansister pipes removal and installation
Disconnect the evaporative emission (EVAP) vapor and vent valve pipes from the evaporative emission (EVAP) canister.
Disconnect the fuel return and feed pipes from the fuel tank.
To avoid system contamination, cap the evaporative emission (EVAP) and fuel pipes.
Use a jack to support the fuel tank.
Fuel tank removal and installation
Detach the fuel tank straps from the frame.
Lower the fuel tank.
Disconnect the fuel sender connector.
Remove the fuel tank from the vehicle.
To Install:
Place the fuel tank under the vehicle.
Connect the fuel sender connector.
Attach the fuel tank straps to the frame. Torque the bolts to 24 ft-lb (32 Nm).
Remove the caps from the evaporative emission (EVAP) and fuel pipes.
Connect the evaporative emission (EVAP) vapor and vent valve pipes to the evaporative emission (EVAP) canister.
Connect the evaporative emission (EVAP) vent valve and fuel tank pressure sensor connectors.
Connect the fuel hose to the fuel tank. Torque the clamp to 22 in-lb (2.5 Nm).
Connect the fuel return and feed pipes to the fuel tank.
Lower the vehicle.
Refill the fuel tank.
Turn on the ignition for 2 seconds, with the engine off, and then turn off the ignition. After 10 seconds, turn the ignition back on with the engine off.
Drain the fuel from the tank into an approved container.
Evaporative emission cansister pipes removal and installation
Disconnect the evaporative emission (EVAP) canister fresh air, solenoid, and purge pipes from the evaporative emission (EVAP) canister.
Disconnect the fuel filler pipe recirculation hose from the fuel tank.
Loosen the fuel fill pipe clamp and disconnect the pipe from the fuel tank.
Disconnect the fuel feed and evaporative emission (EVAP) pipes from the fuel tank.
To avoid system contamination, cap the pipes.
Use a jack to support the fuel tank.
Fuel tank removal and installation
Detach the fuel tank straps from the frame.
Lower the fuel tank.
Disconnect the evaporative emission (EVAP) vent valve, fuel tank pressure sensor, and fuel sender connectors.
Remove the fuel tank from the vehicle.
To Install:
Place the fuel tank under the vehicle.
Connect the evaporative emission (EVAP) vent valve, fuel tank pressure sensor, and fuel sender connectors.
Lift the fuel tank.
Attach the fuel tank straps to the frame. Torque the screws to 24 ft-lb (32 Nm).
Remove the caps from the pipes.
Connect the fuel feed and evaporative emission (EVAP) pipes to the fuel tank.
Connect the fuel fill pipe to the fuel tank. Torque the clamp to 22 in-lb (2.5 Nm).
Connect the fuel filler pipe recirculation hose to the fuel tank.
Connect the evaporative emission (EVAP) canister fresh air, solenoid, and purge pipes to the evaporative emission (EVAP) canister.
Lower the vehicle.
Refill the fuel tank.
Turn on the ignition for 2 seconds, with the engine off, and then turn off the ignition. After 10 seconds, turn the ignition back on with the engine off.
NOTE
Always maintain cleanliness when servicing fuel system components.
Relieve the fuel system fuel pressure.
Drain the fuel tank.
Raise the vehicle.
Disconnect the fuel tank wiring harness connector at the body pass through.
For 3.4L engines, disconnect the quick-connect fitting at the inlet side of the in-pipe fuel filter.
For 3.4L engines, disconnect the quick-connect fitting on the fuel return pipe, near the fuel filter.
Disconnect the fuel tank evaporative emission (EVAP) pipe quick-connect fitting near the fuel filter.
Remove the fuel feed, the fuel return, and the EVAP lines from the fuel pipe retainer.
Remove the retaining nut for the EVAP canister bracket.
Loosen the fuel tank filler pipe hose clamp.
Disconnect the fuel tank filler pipe from the fuel tank.
For 3.5L engines, disconnect the EVAP vent pipe near the fill pipe hose.
NOTE
Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.
With the aid of an assistant, support the fuel tank and remove the fuel tank strap attaching bolts.
Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.
If the fuel tank is not being replaced, go to the Installation Procedure.
Disconnect the fuel tank wiring harness from the fuel sender assembly.
Remove the fuel sender shield from the fuel tank.
Disconnect the fuel feed and return pipe quick-connect fittings at the fuel sender.
Disconnect the EVAP vapor pipe assembly from the fuel sender.
Remove the fuel and/or EVAP pipe assembly from the fuel tank.
Remove the fuel sender assembly.
Remove the EVAP vent solenoid valve.
Remove the EVAP canister.
To install:
Install the EVAP canister.
Install the EVAP vent solenoid valve.
Install the fuel sender assembly.
Install the fuel and/or EVAP pipe assembly.
Connect the EVAP vapor pipe to the fuel sender assembly.
Connect the fuel feed and fuel return pipes at the fuel sender.
NOTE
Use the correct fastener in the correct location. Replacement
fasteners must be the correct part number for that application.
Fasteners requiring replacement or fasteners requiring the use of
thread locking compound or sealant are identified in the service
procedure. Do not use paints, lubricants, or corrosion inhibitors on
fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the
fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.
Install the fuel sender shield to the fuel tank and tighten the shield nuts to 53 inch lbs. (6 Nm).
Connect the fuel tank wiring harness to the fuel sender assembly.
With the aid of an assistant, position and support the fuel tank.
NOTE
Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.
Install the fuel tank retaining strap attaching bolts and tighten the fuel tank retaining strap bolts to 35 ft. lbs. (47 Nm).
Install the EVAP canister retaining nut and tighten the retaining nut to 53 inch lbs. (6 Nm).
Connect the fuel tank filler pipe to the fuel tank and tighten the fuel tank filler pipe hose clamp to 22 inch lbs. (2.5 Nm).
Connect the fuel feed pipe quick-connect fitting at the inlet side of the fuel filter.
Connect the fuel return pipe quick-connect fitting near the fuel filter.
Connect the fuel tank EVAP pipe quick-connect fitting near the fuel filter.
Connect the fuel tank wiring harness connector at the body pass-through.
Lower the vehicle.
Add fuel and reinstall the fuel tank filler pipe cap.
Connect the negative battery cable.
Inspect for fuel leaks with the following procedure:
Turn ON the ignition for 2 seconds.
Turn OFF the ignition for 10 seconds.
Turn ON the ignition.
Inspect for fuel leaks.
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Disconnect the negative battery cable and relieve the fuel system pressure.
Siphon or pump as much fuel as possible out through the fuel filler pipe.
NOTE
Fuel injected vehicles have reservoirs inside the fuel tank to maintain fuel near the fuel pickup during cornering and under low fuel operating conditions. These reservoirs could block siphon tubes or hoses from reaching the bottom of the fuel tank. Repeated attempts using different hose orientations can overcome this obstacle.
Raise and safely support the vehicle.
If equipped with a metal retainer that fastens the filler pipe to the fuel tank, remove the screw attaching the retainer to the fuel tank flange.
Detach the fuel lines and the electrical connector to the fuel tank sending unit. On some vehicles, these are inaccessible on top of the tank. In these cases they must be disconnected with the tank partially removed.
Place a safety support under the fuel tank and remove the bolts or nuts from the fuel tank straps. Allow the straps to swing out of the way.
Partially remove the tank and detach the fuel lines and electrical connector from the sending unit, if not detached previously.
Remove the tank from the vehicle.
To install:
Raise the fuel tank into position in the vehicle. Connect the fuel lines and sending unit electrical connector if it is necessary to connect them before the tank is in the final installed position.
Lubricate the fuel filler pipe with water base tire mounting lubricant and install the tank onto the filler pipe, then bring the tank into final position. Be careful not to deform the tank.
Bring the fuel tank straps around the tank and start the retaining nut or bolt. Align the tank with the straps. If equipped, make sure the fuel tank shields are installed with the straps and are positioned correctly on the tank.
Check the hoses and wiring mounted on the tank top to make sure they are correctly routed and will not be pinched between the tank and body.
Tighten the fuel tank strap retaining nuts or bolts to 20–30 ft. lbs. (28–40 Nm).
If not already connected, connect the fuel hoses and lines which were detached. Make sure the fuel supply, fuel return, if present, and vapor vent connections are made correctly. If not already connected, connect the sending unit electrical connector.
Drain the fuel tank from the filler neck as much as possible.
Raise and safely support the vehicle.
Loosen the clamp and remove the filler hose from the fuel tank.
Disconnect the fuel and EVAP quick-connect fittings at the fuel tank.
Remove the exhaust pipe hangers and allow the exhaust system to drop slightly.
Separate the EVAP fresh air line at the splice.
Remove the fuel tank shield.
Support the fuel tank with a suitable jack.
Remove the two bolts securing the fuel tank straps.
Lower the fuel tank from the vehicle.
Disconnect the electrical connectors from the fuel pump assembly.
Clean the fuel pipe connections with compressed air to prevent contamination during removal.
Disconnect the quick-connect fittings at the fuel sender assembly.
Remove the fuel sender retaining ring and remove the fuel sender assembly. The modular fuel sender assembly will spring-up when the snap ring is removed.
To Install: CAUTION Be careful not to fold or twist the fuel inlet strainer when installing the fuel sender assembly, this will restrict fuel flow. Also, make sure the float arm is able to move freely.
Place a new fuel sender assembly seal on the tank and install the fuel sender assembly.
Holding the fuel sender in place and install the retaining ring.
Connect the quick-connect fittings at the fuel sender assembly.
Connect the electrical connectors.
Place the fuel tank on a suitable jack and raise it in position under the vehicle.
Install the fuel tank strap bolts. Tighten the bolts to 35 lb ft (48 Nm).
Install the fuel tank shield.
Connect the fuel and EVAP quick-connect fittings at the fuel tank.
Connect the EVAP fresh air hose at the splice.
Install the fuel tank filler hose to the fuel tank.
Raise the exhaust and install the exhaust pipe hangers.
Lower the vehicle.
Add fuel and install the fuel filler pipe cap.
Connect the negative battery cable.
Perform the following to pressurize the fuel system;
After removing all connections and wiring from the tank and the sending unit and depressurize fuel system and drain the fuel tank and most importantly TO DISCONNECT THE BATTERY this is what you have to do :
1- Make sure to mark the wires for the sending unit so that you do not have a problem connecting in the correct place.
2- Remove bolts securing spare wheel mounting bracket and remove bracket.
3- Remove tank upper insulation pad.
4- Disconnect fuel pump harness from evaporative loss flange connection
5- Release harness attached to tank retaining straps and reposition harness downward.
6- Disconnect vapor pipe assembly from underbody pipe.
7- Push back collars on quickfit connectors and remove vapor pipe and over-pressure pipe from evaporative loss flange port.
8- Remove bolts securing tank retaining straps.
9- reposition straps upwards for access.
10- Remove strap holding filler housing solenoid block connector to harness and disconnect connector.
11- Disconnect drain tube from aperture seal (small pipe beside big one)
12- Open filler cap and remove filler neck garter spring.
13- Remove filler housing bolts.
14- Displace filler housing from body opening
15- Remove fuel tank.
16- Remove hose from evaporative loss flange and filler neck , ( Bend weld tag upwards to release hose).
17- Remove evaporative loss flange lock ring.
18- Lift flange from tank enough to disconnect fuel pump harness.
19- Remove flange and seal.
20- Inside tank , loosen hose clamps and remove fuel hoses from fuel pump module.
21- Remove fuel pump module and mounting rubber , note position of mounting rubber lugs.
22- Loosen hose clamps and remove two fuel hoses inside tank.
23- Remove tank sending unit.
24- Remove magnetic drain plug and make sure that you clean it well.
That is it your tank is out , and make sure that you mark every thing that you disconnected to install back in its proper place.
If you need any more help please let me know
Hi, i replaced my air filter on my cbr but it wouldn't start for me then i realised that 1 of my fuel lines were not connected properly when i put the fuel tank back on.
After that it was fine, check and make sure that your fuel lines are connected correctly under the fuel tank because they are a tight fit and therefore they can slip off easily if not connected right, you should see that there are 2 thin pipes that connect under the tank and then see if they are connected to the rest of the engine ok, but i'm not sure why it would be overheating on you!
Fuel Tank
Removal & Installation
2002-2004
To Remove: 
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