2004 Chrysler PT Cruiser Base, AutomaticFACTORY OEM SERVICE PROCEDURE

Fuel Pump Module: Installation

  1. Wipe seal area of tank clean. Place a new seal between the tank threads and the pump module opening.
    2. NOTE: The pump has to properly located to the tank for the fuel gauge to work properly.
  2. Position fuel pump module in tank. Make sure the alignment marks line up on the fuel tank and pump module.
    3. 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, see FUEL TANK .
  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 DRBIII® scan tool to pressurize the system and check for leaks.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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