Here's a general outline of the process. Specific steps might vary slightly depending on the engine (2.7L, 3.3L, or 3.5L). Always consult a repair manual specific to your vehicle's year, engine, and trim level for detailed instructions and torque specifications. A Haynes or Chilton manual would be a good investment.
1. Safety First:
* Disconnect the negative battery terminal. This is crucial to prevent sparks and electrical shock.
* Ventilate the area. Work in a well-ventilated space, away from any ignition sources.
* Wear safety glasses and gloves.
* Have a fire extinguisher readily available.
2. Preparation:
* Gather tools: You'll need a socket set (metric), various wrenches, screwdrivers (Phillips and flathead), a fuel pump removal tool (often a specialized tool to remove the retaining ring), a fuel line disconnect tool, jack stands, jack, rags, and possibly a fuel pressure gauge.
* Drain the fuel tank: This is advisable but not always strictly necessary. If you choose to do this, consult your repair manual for the proper procedure. Be aware that gasoline is highly flammable.
* Locate the fuel pump access panel: This is usually located under the rear seat or in the trunk, depending on the model. You'll likely need to remove some interior panels to access it.
3. Accessing the Fuel Pump:
* Remove the access panel: This typically involves removing bolts or clips.
* Disconnect the electrical connector: Carefully unplug the electrical connector from the fuel pump.
* Disconnect the fuel lines: This requires caution. Use the fuel line disconnect tool to avoid damaging the lines. Have rags ready to soak up any spilled fuel. It's highly recommended to relieve fuel pressure in the system before disconnecting lines. Consult your repair manual for the procedure.
* Remove the fuel pump retaining ring: This is where the specialized tool is usually needed. The ring holds the fuel pump assembly in place.
* Lift out the fuel pump assembly: Carefully remove the assembly from the tank. It may be heavy and contain fuel.
4. Replacing the Fuel Pump:
* Install the new fuel pump: Carefully install the new fuel pump assembly into the tank, ensuring it's seated correctly.
* Reinstall the retaining ring: Use the fuel pump removal tool to securely fasten the retaining ring.
* Reconnect the fuel lines: Make sure the connections are secure and leak-free.
* Reconnect the electrical connector: Securely plug the electrical connector back onto the fuel pump.
* Reinstall the access panel: Securely fasten the access panel.
5. Post-Installation:
* Reconnect the negative battery terminal.
* Check for leaks: Carefully inspect all fuel line connections for leaks.
* Start the engine: Let the engine run for a few minutes to ensure the fuel pump is working correctly.
* Check for codes: Use an OBD-II scanner to check for any diagnostic trouble codes (DTCs).
Important Considerations:
* Fuel pressure: A fuel pressure gauge might be used to confirm proper fuel pressure after installation.
* Fuel pump strainer: The fuel pump strainer (or sock) is often integrated with the pump assembly. It's usually a good idea to replace this along with the pump to prevent future problems.
* Professional help: If you're not comfortable performing this repair, it's best to take your vehicle to a qualified mechanic. Improperly installing a fuel pump can lead to serious safety hazards.
This is a general guide, and specific steps may vary depending on your vehicle's configuration. Always refer to a repair manual specific to your 1996 Chrysler Concorde for detailed instructions and safety precautions. Remember, working with fuel is dangerous; take all necessary safety measures.
