All Wheel Drive: Auxiliary

WARNING: This page is about a different car, the 2016 Dodge Journey and 2015 Dodge Journey. However, it is still accessible from the selected car via links, so may be relevant.

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.

WARNING:

The fuel system is under constant high pressure even with engine OFF. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury.

Fig 1: Fuel Pump Module O-Ring

Courtesy of CHRYSLER GROUP, LLC

CAUTION:

Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced.

Clean the rubber O-ring seal area of the fuel tank module opening and install a new rubber O-ring seal.

Fig 2: Auxiliary Fuel Pump Module Internal Fuel Line
Courtesy of CHRYSLER GROUP, LLC
Reconnect the internal fuel line to the auxiliary fuel pump module.
Lower the auxiliary fuel pump module into the fuel tank using caution not to bend the float arm.

Fig 3: Tab Location Small Module
Courtesy of CHRYSLER GROUP, LLC

NOTE:
The fuel pump module must be properly located in the fuel tank for the fuel level gauge to work properly.
Align the rubber O-ring seal and rotate the auxiliary fuel pump module to the orientation noted or marked during removal. This step must be performed for the fuel level gauge to work properly.

Fig 4: Small Lock Ring Tool
Courtesy of CHRYSLER GROUP, LLC
Position the lock ring over the top of the fuel pump module flange.
Position the (special tool #10189, Wrench, DEF Module Lock Ring) into the notches on the outside edge of the lock ring.
Install a 1/2 inch drive breaker bar into the (special tool #10189, Wrench, DEF Module Lock Ring).
Rotate the breaker bar clockwise until all seven notches of the lock ring have engaged.
Reinstall the fuel tank into the vehicle. Refer to TANK, FUEL, INSTALLATION .