Here's a general overview of the process. This is NOT a substitute for a repair manual. Variations exist depending on engine and trim level:
1. Safety First:
* Disconnect the negative battery terminal. This prevents accidental sparks that could ignite fuel vapors.
* Work in a well-ventilated area. Fuel vapors are highly flammable.
* Wear safety glasses and gloves.
2. Preparation:
* Locate the fuel pump access panel. This is usually located under the rear passenger seat or in the cargo area. Consult your repair manual for the exact location.
* Gather your tools. You'll likely need:
* Socket set (various sizes)
* Ratchet and extensions
* Torque wrench
* Fuel pump pliers (or a similar tool to clamp the fuel lines)
* New fuel pump assembly (ensure it's the correct one for your vehicle)
* Safety glasses
* Gloves
* Jack and jack stands (if necessary for easier access)
* Shop rags or absorbent material
* Possibly a fuel pressure gauge
3. Removal:
* Remove the access panel. This usually involves removing some screws or bolts.
* Disconnect the electrical connector from the fuel pump.
* Disconnect the fuel lines. This is where the fuel line pliers are crucial. Use caution to avoid spilling fuel. You might need to use rags to absorb any spilled fuel. Some systems require disconnecting the fuel pressure regulator as well.
* Remove the fuel pump retaining ring. This may be a clamp or a series of bolts.
* Carefully lift out the fuel pump assembly. Take note of how things are assembled to avoid issues during reassembly.
4. Installation:
* Inspect the fuel tank. Check for any debris or damage.
* Install the new fuel pump assembly. Make sure the gasket is properly seated.
* Connect the fuel lines. Tighten securely using the proper torque specification from your repair manual.
* Reconnect the electrical connector.
* Reinstall the retaining ring.
* Reinstall the access panel.
5. Final Steps:
* Reconnect the negative battery terminal.
* Check for leaks. Inspect all connections for any fuel leaks.
* Start the engine and check for proper fuel pressure. (This might require a fuel pressure gauge)
Important Considerations:
* Fuel Pressure: Before disconnecting the fuel lines, you might need to relieve pressure in the fuel system. Your repair manual will detail how to do this safely.
* Fuel Pump Strainer: The fuel pump often includes a fuel filter or strainer. Replace this as well.
* Gaskets and Seals: Use new gaskets and seals when reinstalling the fuel pump assembly to prevent leaks.
* Torque Specifications: Use a torque wrench to tighten bolts and connections to the manufacturer's specifications.
This is a general outline. Always refer to a repair manual specific to your 1999 Dodge Durango for detailed instructions and safety precautions. If you're not comfortable performing this repair yourself, take your vehicle to a qualified mechanic. Working with fuel systems can be dangerous if not done correctly.
