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AWD Dodge Avenger II facelift

Fuel System 12 illustrations ~987 words

AWD

The all wheel drive (AWD) vehicles with the saddle fuel tank configurations have a main (1) and auxiliary (2) fuel level sending units.

The main fuel level sending unit located on the main fuel pump reservoir (1) is serviceable. Refer to SENDING UNIT AND SENSOR, FUEL LEVEL, REMOVAL .

The auxiliary fuel level sending unit (2) is integrated with the auxiliary fuel pump module. The auxiliary fuel pump module and the fuel level sending unit is serviced as an assembly. Refer to MODULE, FUEL PUMP, REMOVAL .

WARNINGThe fuel system is under constant pressure even with engine off. Until the fuel pressure has been properly relieved from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Wear protective clothing and eye protection. Make sure the area in which the vehicle is being serviced is in a well ventilated area.

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  1. Remove fuel filler cap.
  2. Remove the rear seat cushion.
  3. Remove fuel pump module cover (1). WARNING: Risk of injury to eyes and skin from contact with fuel. Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked and approved containers. Failure to follow these instructions may result in possible serious or fatal injury.
  4. Release the fuel system pressure. Refer to «FUEL DELIVERY, GAS, STANDARD PROCEDURE»(ref-485510-S12963059542012071300000) .
  5. Disconnect the quick connect fitting (3) of the fuel supply line from the fuel pump module. Refer to «FITTING, QUICK CONNECT, STANDARD PROCEDURE»(ref-485510-S02478018532012071300000) .
  6. Remove the fuel pump module lock ring using SAE Fuel Pump Lock Ring Wrench (special tool #9340, SAE Fuel Pump Lock Ring Wrench).
  7. Note the fuel pump location on the top of the fuel tank. NOTE: The pump has to be properly located to the tank for the fuel gauge to work properly.
  8. Push down on fuel pump module and remove lock ring.
  9. Pull module up out of fuel tank, make sure that you do not spill fuel inside of vehicle.
  10. Drain fuel from fuel pump module into an approved fuel storage container. Do not spill fuel in interior of vehicle.
  11. Transfer fuel from fuel tank into an approved fuel storage container. Refer to «FUEL DELIVERY, GAS, STANDARD PROCEDURE»(ref-485510-S12963059542012071300000) .
  12. Raise and support the vehicle.
  13. Remove close-out panels (1) and (2).
  14. Remove the exhaust system. Refer to «REMOVAL»(ref-485503-S03308939842012071300000) .
  15. On vehicles equipped with a convertible top, remove the two front bolts (1) from the cross-braces (2).
  16. Disconnect the quick connect fitting (1) from the fuel tank vapor line (2). Refer to «FITTING, QUICK CONNECT, STANDARD PROCEDURE»(ref-485510-S02478018532012071300000) .
  17. Disconnect the quick connect fitting (2) and remove the fuel tube vent line (1). Refer to «FITTING, QUICK CONNECT, STANDARD PROCEDURE»(ref-485510-S02478018532012071300000) .
  18. Loosen the hose clamp (3) and remove the fuel filler tube (4) from the fuel tank.
  19. Disconnect the quick connect fitting (1) from the fuel supply line. Refer to «FITTING, QUICK CONNECT, STANDARD PROCEDURE»(ref-485510-S02478018532012071300000) . WARNING: Support the fuel tank with a transmission jack or equivalent. Use straps to secure the fuel tank to the jack. Failure to properly support and secure the fuel tank during removal may cause fuel to spill or the fuel tank to fall from the jack.
  20. Use a transmission jack to support fuel tank (3), remove fuel tank strap bolts (2) and straps (1).
  21. Lower fuel tank (3) from vehicle.
  22. If fuel tank is to be replaced, remove fuel line (1) from fuel tank.
  23. If fuel tank is to be replaced, remove heat shield (1) from fuel tank.
  1. If fuel tank was replaced, install heat shield (1) to fuel tank.
  2. Install o-ring seal and fuel pump module in marked location.
  3. Install fuel pump module lock ring, push module down and start lock ring.
  4. Finish installation of the fuel pump module lock ring using SAE Fuel Pump Lock Ring Wrench (special tool #9340, SAE Fuel Pump Lock Ring Wrench).
  5. Install fuel supply line (1) to fuel tank and connect to fuel pump module. Refer to «FITTING, QUICK CONNECT, STANDARD PROCEDURE»(ref-485510-S02478018532012071300000) . WARNING: Support the fuel tank with a transmission jack or equivalent. Use straps to secure the fuel tank to the jack. Failure to properly support and secure the fuel tank during removal may cause fuel to spill or the fuel tank to fall from the jack.
  6. Position fuel tank onto a transmission jack or equivalent and raise the fuel tank (3) into vehicle position.
  7. Install the straps (1) and fuel tank strap bolts (2). Tighten to 48 N.m (35 ft. lbs.).
  8. Install fuel filler tube (4) to the fuel tank. Tighten hose clamp (3) to 3 N.m (27 in. lbs.).
  9. Install the fuel tube vent line (1) to the quick connect fitting (2). Refer to «FITTING, QUICK CONNECT, STANDARD PROCEDURE»(ref-485510-S02478018532012071300000) .
  10. Connect the tank vapor line (2) quick connect fitting (1). Refer to «FITTING, QUICK CONNECT, STANDARD PROCEDURE»(ref-485510-S02478018532012071300000) .
  11. Connect the quick connect fitting (1) to the fuel supply line. Refer to «FITTING, QUICK CONNECT, STANDARD PROCEDURE»(ref-485510-S02478018532012071300000) .
  12. On vehicles equipped with a convertible top, install the two front bolts (1) to the cross-braces (2). Tighten bolts to 48 N.m (35 ft. lbs.).
  13. Install the exhaust system. Refer to «INSTALLATION»(ref-485503-S25516146662012071300000) .
  14. Install close-out panels (1) and (2).
  15. Lower vehicle.
  16. Connect fuel pump/module electrical connector (2).
  17. Install fuel pump module cover (1).
  18. Install rear seat cushion.
  19. Fill fuel tank and install fuel filler cap.
  20. Connect negative battery cable. NOTE: After servicing the fuel system, one or more Diagnostic Trouble Codes (DTC's) may have been stored in Powertrain Control Module (PCM) memory due to disconnecting fuel pump module circuit. A diagnostic scan tool must be used to erase a DTC.
  21. Use the scan tool to pressurize the fuel system. Check for leaks.

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  1. Disconnect and isolate negative battery cable at battery.
  2. Remove fuel cap.
  3. Remove the inner splash shield. Refer to «SHIELD, SPLASH, REAR WHEELHOUSE, REMOVAL»(ref-485483-S03877425932012071300000) .
  4. Disconnect the quick connect fitting (2) and remove the fuel tube vent line (1).
  5. Loosen the hose clamp (3) and remove the fuel filler tube (4) from the fuel tank.
  6. Remove filler tube mounting bracket bolt (1) from bracket (2) and body mount (3).
  7. Remove fuel filler tube (2) from the fuel door housing assembly (1).