Tuesday, December 10, 2013
How to Replace an In Tank Pump on a 2005 Dodge 2500
A Dodge 2500 is a pickup truck with a carrying capacity of at least 3/4-ton. The 2005 model may have several different engines, most often an eight-cylinder 5.7-liter engine with sequential fuel injection. This requires a fuel pump to maintain the fuel under high pressure. The fuel pump in a 2005 Dodge 2500 is inside the fuel tank, requiring you to remove the fuel tank to replace the fuel pump.
Instructions
- 1
Disconnect the cable from the negative battery terminal with a socket wrench. This prevents the accidental discharge of fuel during the fuel pump replacement. Detach the electrical wiring harness and fuel lines from the fuel pump.
2Siphon the fuel from the fuel tank into a container approved for gasoline. Place a floor jack under the vehicle and support the fuel tank with a floor jack. Disconnect the mounting bolts for the fuel tank with a socket wrench and release the retaining straps for the fuel tank. Lower the floor jack to remove the fuel tank from the vehicle.
3Attach special tool 6856 to the lock nut on the fuel pump and connect a socket wrench to the special tool. Turn the lock nut for the fuel pump counterclockwise with the socket wrench and remove the lock nut from the fuel pump. Lift the fuel pump out of the fuel tank.
4Install the new fuel pump into the fuel tank and attach its lock nut. Fasten the lock nut by turning it clockwise with a socket wrench and special tool 6856.
5Raise the fuel tank in position with the floor jack. Attach the retaining straps to the fuel tank and connect the mounting bolts to the fuel tank with a socket wrench. Lower the floor jack.
6Attach the fuel line and wiring harness to the fuel pump. Connect the negative battery cable with a socket wrench. Fill the fuel tank with fuel, start the engine and check for fuel leaks.
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