Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2004 Chrysler PT Cruiser Base, StandardFACTORY OEM SERVICE PROCEDURE
Fuel Pump Module: Removal
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. THIS MAY RESULT IN PERSONAL INJURY OR DEATH.
- Remove fuel filler cap and perform FUEL SYSTEM PRESSURE RELEASE PROCEDURE .
- Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose.
- Remove the negative battery cable.
- Raise vehicle and support.
- Remove fuel tank, refer to FUEL TANK .
- Clean top of tank to remove loose dirt and debris.
- Mark the fuel pump location on the top of the fuel tank.
- Disconnect fuel filter lines from fuel pump module.
NOTE:
The pump has to be properly located to the tank for the fuel gauge to work properly.
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. USE CAUTION TO AVOID PERSONAL INJURY.
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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