Here's a general overview of the process. Specific steps may vary slightly depending on the year and model of your Durango. Always consult a repair manual specific to your vehicle's year and engine for detailed instructions and diagrams. This information is for general guidance only.
Safety Precautions:
* Disconnect the negative battery terminal. This is crucial to prevent sparks.
* Work in a well-ventilated area. Gasoline fumes are highly flammable and dangerous.
* Wear safety glasses and gloves.
* Have a fire extinguisher nearby.
* Properly dispose of old fuel and components according to local regulations.
General Steps:
1. Lower the fuel tank: This is often the most challenging part. You'll likely need to access the tank from underneath the vehicle. This may involve:
* Raising the vehicle securely on jack stands. Never work under a vehicle supported only by a jack.
* Removing the fuel filler neck access panel (if applicable).
* Disconnecting the fuel lines (be prepared for some fuel spillage). Use fuel line clamps to prevent leaks during and after disconnecting.
* Detaching electrical connectors to the fuel pump and sending unit.
* Unbolting the fuel tank straps. This usually requires several bolts. Some Durangos require lowering the exhaust system for easier access.
* Carefully lowering the fuel tank. You may need to support the tank with a jack or straps as you lower it.
2. Access the fuel pump: The fuel pump is typically located inside the fuel tank. You'll likely need to:
* Remove the fuel pump access cover. This is usually a circular cover secured with bolts.
* Carefully remove the retaining ring or clamp holding the fuel pump in place.
3. Replace the fuel pump:
* Disconnect the electrical connector from the old pump.
* Remove the old fuel pump.
* Install the new fuel pump, ensuring it's properly seated.
* Reconnect the electrical connector.
* Reinstall the retaining ring or clamp.
* Reinstall the fuel pump access cover.
4. Reinstall the fuel tank:
* Carefully raise the fuel tank back into position.
* Reconnect the fuel lines securely. Use new fuel line clamps if necessary.
* Reconnect the electrical connectors.
* Reattach the fuel tank straps.
* Reinstall the fuel filler neck access panel (if applicable).
* Lower the vehicle.
5. Reconnect the battery terminal.
6. Prime the fuel system: You may need to cycle the ignition key (without starting) several times to prime the fuel system before attempting to start the engine.
Important Considerations:
* Fuel pressure: Some models require relieving fuel pressure before starting the process. Consult your vehicle's repair manual.
* Fuel tank venting: Ensure the tank is properly vented before and after the repair.
* Fuel pump assembly: The fuel pump often comes as a module with the fuel level sending unit, which needs to be transferred carefully.
* O-rings and seals: Replace any damaged O-rings and seals on the fuel pump assembly to prevent leaks.
This is a simplified guide. Again, a factory repair manual for your specific Dodge Durango model and year is absolutely essential for a successful and safe repair. Attempting this repair without the proper knowledge and tools can lead to damage to your vehicle or personal injury. If you are uncertain about any step, seek professional help.
