Here's a general outline, but remember this is not a substitute for a detailed repair manual specific to your 1991 Dodge Stealth. Consult a factory service manual or a reputable online resource with detailed instructions and diagrams for your specific model. Improper procedures can lead to injury or damage.
General Steps (Consult your repair manual for precise details and torque specifications):
1. Safety First: Disconnect the negative battery terminal. This is crucial to prevent sparks near fuel. Work in a well-ventilated area. Consider using safety glasses and gloves.
2. Prepare the Vehicle: Raise the vehicle securely on jack stands. Never work under a vehicle supported only by a jack.
3. Drain the Fuel Tank: This is essential to minimize the amount of fuel you're working around. Use a siphon pump to remove as much fuel as possible. Dispose of the fuel properly according to local regulations.
4. Disconnect Fuel Lines: Carefully disconnect the fuel lines from the tank. You'll likely need fuel line disconnect tools to avoid damaging the lines. Mark the lines to ensure proper reconnection. Have rags ready to soak up any spilled fuel.
5. Disconnect Electrical Connections: Disconnect the fuel level sender unit and any other electrical connections to the fuel tank.
6. Remove the Fuel Tank Straps: Locate and carefully remove the straps or bolts securing the fuel tank to the vehicle. These are usually located under the car. You may need to loosen some other components to access them.
7. Lower the Fuel Tank: Gently lower the fuel tank. It may be heavy and awkward, so have assistance if needed. Be mindful of any brake lines, exhaust components, or other parts that might interfere.
8. Access the Fuel Pump: Once the tank is lowered or removed, you should have access to the fuel pump assembly. This typically involves removing a cover or access panel on the top of the tank.
9. Replace the Fuel Pump: Follow the instructions provided with your replacement fuel pump for installation.
10. Reassembly: Reassemble everything in the reverse order of removal. Double-check all connections, ensuring everything is secure and leak-free.
11. Check for Leaks: Before lowering the vehicle, carefully inspect all fuel connections for leaks.
12. Lower the Fuel Tank and Secure: Carefully raise and secure the fuel tank.
13. Reconnect Everything: Reconnect the fuel lines, electrical connections, and straps.
14. Lower the Vehicle: Lower the vehicle and reconnect the negative battery terminal.
15. Test the System: Start the vehicle and check for any leaks or malfunctions.
Critical Considerations:
* Fuel Vapor: Fuel vapors are highly flammable and potentially explosive. Ensure adequate ventilation.
* Static Electricity: Static discharge can ignite fuel vapors. Ground yourself properly before working on the fuel system.
* Repair Manual: A factory service manual or a reputable repair guide specific to your 1991 Dodge Stealth is absolutely essential. This guide provides crucial details and diagrams not included in this general overview.
This is a complex procedure. If you're not comfortable performing this repair yourself, take your vehicle to a qualified mechanic. The risk of fire or injury makes professional assistance highly recommended.
