Here's a general overview of the process. Specific steps may vary slightly depending on the engine type (3.0L, 3.5L, or 3.8L). Always consult a repair manual specific to your 1996 Chrysler Concorde's engine for precise instructions and torque specifications.
Safety Precautions:
* Disconnect the negative battery terminal before starting any work.
* Work in a well-ventilated area. Fuel fumes are highly flammable and potentially toxic.
* Have a fire extinguisher readily available.
* Use proper safety glasses and gloves.
* Wear clothing that covers your skin.
* Drain the fuel tank as much as possible before starting. This reduces the amount of fuel you need to work around. You can do this by carefully siphoning the fuel (with proper safety precautions) or by driving the car until the tank is nearly empty.
General Steps:
1. Locate the Fuel Pump: The fuel pump is usually located inside the fuel tank, typically accessed from underneath the vehicle.
2. Lower the Fuel Tank (Often Necessary): This is the most challenging part. You'll likely need to:
* Support the fuel tank securely. Use jack stands to support the tank's weight after lowering it. NEVER work under a vehicle supported only by a jack.
* Disconnect the fuel lines: This requires carefully releasing the fuel line clips and possibly using fuel line disconnect tools to avoid damaging the lines. Be prepared for some fuel spillage. Use clean rags to soak up any spills.
* Disconnect the electrical connector: This connector goes to the fuel pump.
* Disconnect the fuel tank straps: These straps hold the fuel tank in place.
3. Access the Fuel Pump: Once the tank is lowered enough, you'll likely see an access plate on top of the tank. This plate usually needs to be removed to reach the fuel pump.
4. Remove the Fuel Pump: This typically involves:
* Removing the retaining ring or bolts securing the pump assembly.
* Carefully removing the fuel pump assembly from the tank. Note the position and orientation of all components for reassembly.
5. Install the New Fuel Pump:
* Install the new fuel pump assembly. Ensure it is properly seated and oriented.
* Reinstall the retaining ring or bolts.
* Reinstall the access plate.
6. Raise the Fuel Tank: Carefully raise the fuel tank back into its position. Secure it with the straps.
7. Reconnect Everything:
* Reconnect the fuel lines, ensuring they are properly secured.
* Reconnect the electrical connector.
* Reconnect the negative battery terminal.
8. Check for Leaks: Inspect all fuel line connections for leaks.
9. Prime the Fuel System (Often Necessary): Some vehicles require priming the fuel system after a fuel pump replacement. This often involves turning the ignition key on and off several times (without starting the engine) to allow the pump to build pressure. Consult your repair manual for the correct procedure.
10. Start the Engine: Start the engine and check for any leaks or unusual sounds.
Important Considerations:
* Fuel Pressure: You might need a fuel pressure gauge to test the system after installation.
* Fuel Pump Module: The fuel pump is often part of a larger assembly called a fuel pump module. You may need to replace the entire module rather than just the pump itself.
* Repair Manual: A service manual specific to your 1996 Chrysler Concorde is essential. This will provide detailed diagrams, torque specifications, and specific instructions. Chilton and Haynes are reputable sources for these manuals.
This is a complex procedure. Improperly installing the fuel pump can lead to serious damage to your vehicle or even injury. If you are not comfortable with the process, seeking professional help from a qualified mechanic is the safest and most reliable option.
