Chrysler PT Cruiser 2001 Service Manual Supplement page 1099

14 - 12 FUEL SYSTEM
REMOVAL AND INSTALLATION (Continued)
Fig. 18 Electrical Connector
(6) Connect the fuel line (Fig. 17). Refer to Quick
Connect Fittings in this section.
(7) Connect fuel fill tube to tank inlet. Tighten
hose clamp to 3.5 N·m (31 in. lbs.) torque.
(8) Position fuel tank straps. Tighten fuel tank
strap bolts to 23 N·m (250 in. lbs.) torque (Fig. 16).
Remove transmission jack. Ensure straps are not
twisted or bent.
(9) Lower vehicle.
(10) Fill fuel tank, install filler cap.
(11) Install the negative battery cable.
(12) Install the air cleaner lid, connect the inlet air
temperature sensor and makeup air hose.
(13) Use the DRB scan tool ASD Fuel System Test
to pressurize the fuel system. Check for leaks.
FUEL PUMP MODULE
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.
REMOVAL
(1) Remove fuel filler cap and perform Fuel Sys-
tem Pressure Release procedure.
(2) Remove the air cleaner lid, disconnect the inlet
air temperature sensor and makeup air hose.
(3) Remove the negative battery cable.
(4) Raise vehicle and support.
(5) Remove fuel tank, refer to the Fuel Tank
Removal in this section.
(6) Clean top of tank to remove loose dirt and
debris.
(7) Disconnect fuel filter lines from fuel pump
module.
(8) Using Special Tool #6856 Fuel Pump Module
Ring Spanner, remove locknut to release pump mod-
ule (Fig. 19).
Fig. 19 Fuel Pump Module Locknut
WARNING: THE FUEL RESERVOIR OF THE FUEL
PUMP MODULE DOES NOT EMPTY OUT WHEN THE
TANK IS DRAINED. THE FUEL IN THE RESERVOIR
MAY SPILL OUT WHEN THE MODULE IS REMOVED.
(9) Remove fuel pump module and seal from tank.
Discard seal.
INSTALLATION
(1) Wipe seal area of tank clean. Place a new seal
between the tank threads and the pump module
opening.
(2) Position fuel pump module in tank. Make sure
the alignment tab on the underside of the pump mod-
ule flange sits in the corresponding notch in the fuel
tank.
CAUTION: Over tightening the pump lock ring may
result in a leak.
(3) While holding the pump module in position,
install locknut. Tighten locknut to 74.5 N·m (55 ft.
lbs) torque using special tool #6856.
(4) Install fuel tank, refer to the Fuel Tank Instal-
lation in this section.
(5) Lower vehicle.
(6) Install the negative battery cable.
(7) Install the air cleaner lid, connect the inlet air
temperature sensor and makeup air hose.
(8) Fill fuel tank with clean fuel. Use the DRB
scan tool to pressurize the system and check for
leaks.
PT