2000 DODGE NEON engine

FUEL TUBES/LINES/HOSES AND CLAMPS
OPERATION
Also refer to Quick-Connect Fittings.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRES-
SURE MUST BE RELEASED. REFER TO THE FUEL
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP.
Inspect all hose connections such as clamps, cou-
plings and fittings to make sure they are secure and
leaks are not present. The component should be
replaced immediately if there is any evidence of deg-
radation that could result in failure.
Never attempt to repair a plastic fuel line/tube.
Replace as necessary.
Avoid contact of any fuel tubes/hoses with other
vehicle components that could cause abrasions or
scuffing. Be sure that the plastic fuel lines/tubes areproperly routed to prevent pinching and to avoid heat
sources.
The lines/tubes/hoses used on fuel injected vehicles
are of a special construction. This is due to the
higher fuel pressures and the possibility of contami-
nated fuel in this system. If it is necessary to replace
these lines/tubes/hoses, only those marked EFM/EFI
may be used.
If equipped:The hose clamps used to secure rub-
ber hoses on fuel injected vehicles are of a special
rolled edge construction. This construction is used to
prevent the edge of the clamp from cutting into the
hose. Only these rolled edge type clamps may be
used in this system. All other types of clamps may
cut into the hoses and cause high-pressure fuel leaks.
Use new original equipment type hose clamps.
Tighten hose clamps to 3 N´m (25 in. lbs.) torque.
SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE
PROCEDURE
(1) Remove Fuel Pump relay from Power Distribu-
tion Center (PDC). For location of relay, refer to label
on underside of PDC cover.
(2) Start and run engine until it stalls.
(3) Attempt restarting engine until it will no
longer run.
(4) Turn ignition key to OFF position.
CAUTION: Steps 1, 2, 3 and 4 must be performed to
relieve high pressure fuel from within fuel rail. Do
not attempt to use following steps to relieve this
pressure as excessive fuel will be forced into a cyl-
inder chamber.
(5) Place a rag or towel below fuel line quick-con-
nect fitting at fuel rail.
(6) Return fuel pump relay to PDC.
(7) One or more Diagnostic Trouble Codes (DTC's)
may have been stored in PCM memory due to fuel
pump relay removal. The DRB IIItscan tool must be
used to erase a DTC.
INJECTOR CONNECTOR
REMOVAL
(1) Disconnect electrical connectors at the fuel
injectors. To remove connector refer to (Fig. 8). Pull
the red colored slider away from injector (1). While
pulling the slider, depress tab (2) and remove connec-
tor (3) from injector. The factory fuel injection wiring
harness is numerically tagged (INJ 1, INJ 2, etc.) for
injector position identification. If harness is not
tagged, make note of wiring location before removal.
Fig. 6 Plastic Quick-Connect Fittings
1 ± CASING
2 ± WINDOW
3 ± RETAINER TAB
4 ± NIPPLE
5 ± O RINGS
6 ± WINDOW
7 ± RETAINER ªEARº
14 - 8 FUEL SYSTEMPL
DESCRIPTION AND OPERATION (Continued)

(3) Squeeze retainer tabs together and pull fuel
tube/quick-connect fitting assembly off of fuel tube
nipple. The retainer will remain on fuel tube.
INSTALLATION
CAUTION: Never install a quick-connect fitting
without the retainer being either on the fuel tube or
already in the quick-connect fitting. In either case,
ensure the retainer locks securely into the quick-
connect fitting by firmly pulling on fuel tube and fit-
ting to ensure it is secured.
(1) Using a clean lint free cloth, clean the fuel tube
nipple and retainer.
(2) Prior to connecting the fitting to the fuel tube,
coat the fuel tube nipple with clean 30 weight engine
oil.
(3) Push the quick-connect fitting over the fuel
tube until theretainer seats and a click is heard.
(4) The plastic quick-connect fitting has windows
in the sides of the casing. When the fitting com-
pletely attaches to the fuel tube, the retainer locking
ears and the fuel tube shoulder are visible in the
windows. If they are not visible, the retainer was not
properly installed (Fig. 9).Do not rely upon the
audible click to confirm a secure connection.
(5) Connect negative cable to battery or auxiliary
jumper terminal.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay remains energized
for either 7 minutes, until the test is stopped, or
until the ignition switch is turned to the Off posi-
tion.(6) Use the DRB scan tool ASD Fuel System Test
to pressurize the fuel system. Check for leaks.
TWO-TAB TYPE FITTING
This type of fitting is equipped with tabs located on
both sides of the fitting (Fig. 10). These tabs are sup-
plied for disconnecting the quick-connect fitting from
component being serviced.
CAUTION: The interior components (O-rings, spac-
ers) of this type of quick-connect fitting are not ser-
viced separately, but new plastic retainers are
available. Do not attempt to repair damaged fittings
or fuel lines/tubes. If repair is necessary, replace
the complete fuel tube assembly.
WARNING:
THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES, FIT-
TINGS OR LINES, THE FUEL SYSTEM PRESSURE
MUST BE RELEASED. REFER TO THE FUEL PRES-
SURE RELEASE PROCEDURE IN THIS GROUP.
DISCONNECTION/CONNECTION
(1) Perform fuel pressure release procedure. Refer
to Fuel Pressure Release Procedure in this group.
(2) Disconnect negative battery cable from battery
or auxiliary jumper terminal.
(3) Clean fitting of any foreign material before dis-
assembly.
(4) To disconnect quick-connect fitting, squeeze
plastic retainer tabs (Fig. 10) against sides of quick-
connect fitting with your fingers. Tool use is not
required for removal and may damage plastic
retainer. Pull fitting from fuel system component
Fig. 9 Plastic Quick-Connect Fitting/Fuel Tube
Connection
1 ± WINDOW
2 ± TAB (2)
3 ± EAR
4 ± SHOULDER (ON TUBE)
Fig. 10 Typical Two-Tab Type Quick-Connect Fitting
1 ± TAB(S)
2 ± QUICK-CONNECT FITTING
14 - 10 FUEL SYSTEMPL
SERVICE PROCEDURES (Continued)

being serviced. The plastic retainer will remain on
component being serviced after fitting is discon-
nected. The O-rings and spacer will remain in quick-
connect fitting connector body.
(5) Inspect quick-connect fitting body and compo-
nent for damage. Replace as necessary.
CAUTION:
When the quick-connect fitting was dis-
connected, the plastic retainer will remain on the com-
ponent being serviced. If this retainer must be
removed, very carefully release the retainer from the
component with two small screwdrivers. After removal,
inspect the retainer for cracks or any damage.
(6) Prior to connecting quick-connect fitting to
component being serviced, check condition of fitting
and component. Clean parts with a lint-free cloth.
Lubricate with clean engine oil.
(7) Insert quick-connect fitting to component being
serviced and into plastic retainer. When a connection
is made, a click will be heard.
(8) Verify a locked condition by firmly pulling on
fuel tube and fitting (15-30 lbs.).
(9) Connect negative cable to battery or auxiliary
jumper terminal.
(10) Start engine and check for leaks.
PLASTIC RETAINER RING TYPE FITTING
This type of fitting can be identified by the use of a
full-round plastic retainer ring (Fig. 11) usually black
in color.
CAUTION: The interior components (O-rings, spac-
ers, retainers) of this type of quick-connect fitting
are not serviced separately. Do not attempt to repair
damaged fittings or fuel lines/tubes. If repair is nec-
essary, replace the complete fuel tube assembly.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRES-
SURE MUST BE RELEASED. REFER TO THE FUEL
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP.
DISCONNECTION/CONNECTION
(1) Perform fuel pressure release procedure. Refer
to Fuel Pressure Release Procedure in this section.
(2) Disconnect negative battery cable from battery
or auxiliary jumper terminal.
(3) Clean fitting of any foreign material before dis-
assembly.
(4) To release fuel system component from quick-
connect fitting, firmly push fitting towards compo-nent being serviced while firmly pushing plastic
retainer ring into fitting (Fig. 11). With plastic ring
depressed, pull fitting from component.The plastic
retainer ring must be pressed squarely into fit-
ting body. If this retainer is cocked during
removal, it may be difficult to disconnect fit-
ting. Use an open-end wrench on shoulder of
plastic retainer ring to aid in disconnection.
(5) After disconnection, plastic retainer ring will
remain with quick-connect fitting connector body.
(6) Inspect fitting connector body, plastic retainer
ring and fuel system component for damage. Replace
as necessary.
(7) Prior to connecting quick-connect fitting to
component being serviced, check condition of fitting
and component. Clean parts with a lint-free cloth.
Lubricate with clean engine oil.
(8) Insert quick-connect fitting into component
being serviced until a click is felt.
(9) Verify a locked condition by firmly pulling on
fuel tube and fitting (15-30 lbs.).
(10) Connect negative battery cable to battery or
auxiliary jumper terminal.
(11) Start engine and check for leaks.
Fig. 11 Plastic Retainer Ring Type Fitting
1 ± FUEL TUBE
2 ± QUICK CONNECT FITTING
3 ± PUSH
4 ± PLASTIC RETAINER
5 ± PUSH
6 ± PUSH
7 ± PUSH
8 ± PUSH
PLFUEL SYSTEM 14 - 11
SERVICE PROCEDURES (Continued)

REMOVAL AND INSTALLATION
AUTOMATIC SHUTDOWN RELAY
The relay is located in the Power Distribution Cen-
ter (PDC) (Fig. 12). The PDC is located next to the
battery in the engine compartment. For the location
of the relay within the PDC, refer to the PDC cover
for location. Check electrical terminals for corrosion
and repair as necessary.
FUEL PUMP RELAY
The fuel pump relay is located in the PDC. The
inside top of the PDC cover has a label showing relay
and fuse location.
FUEL PUMP MODULE
REMOVAL
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE.
(1) Drain the fuel. Refer to Draining Fuel Tank in
the Fuel Tank section of this group.
WARNING: THE FUEL RESERVOIR OF THE FUEL
PUMP MODULE DOES NOT EMPTY OUT WHEN THE
TANK IS DRAINED. THE FUEL IN THE RESERVOIR
WILL SPILL OUT WHEN THE MODULE IS
REMOVED.
(2) Remove fuel tank, refer to the Fuel Tank
removal/installation section.
(3) Lower tank.(4) Use Special Tool 6856 to remove fuel pump
module locknut (Fig. 15).
(5) Remove fuel pump and O-ring seal from tank.
Discard old seal.
INSTALLATION
(1) Wipe seal area of tank clean and place a new
seal in position in the tank opening.
(2) Position fuel pump in the tank. Make sure the
alignment tab on the underside of the fuel pump
module flange sits in the notch on the fuel tank (Fig.
14).
(3) Position the locknut over the fuel pump mod-
ule.
Fig. 12 Power Distribution Center (PDC)
Fig. 13 Fuel Pump Module Removal
1 ± FUEL FILTER/PRESSURE REGULATOR
2 ± FUEL LINE
3 ± LOCKNUT
Fig. 14 Alignment Tab
14 - 12 FUEL SYSTEMPL

(4) Tighten the locknut using Special Tool 6856 to
55 N´m (40.5 ft. lbs.) (Fig. 15).
CAUTION: Over tightening the pump lock ring may
result in a leak.
(5) Install fuel tank, refer to the Fuel Tank remov-
al/installation section.
(6) Lower vehicle.
(7) Fill fuel tank. Check for leaks.
FUEL FILTER / PRESSURE REGULATOR
REMOVAL
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE, EVEN WITH ENGINE OFF.
BEFORE SERVICING THE FUEL FILTER/FUEL
PRESSURE REGULATOR, THE FUEL SYSTEM
PRESSURE MUST BE RELEASED.
(1) Refer to Fuel System Pressure Release in the
Fuel Delivery System section of this group.
The fuel filter/fuel pressure regulator is located on
the top of fuel pump module. Fuel pump module
removal is not necessary.
(2) Raise vehicle on hoist.
(3) Disconnect fuel supply line at the Filter/Regu-
lator nipple (refer to Quick Connect Fittings in this
section).
(4) Depress locking spring tab on side of Fuel/Reg-
ulator (Fig. 16) and rotate 90É counter-clockwise and
pull out.
NOTE: Make sure that the upper and lower O-rings
are on the Filter/Regulator assembly.
INSTALLATION
Lightly lubricate the O-rings with engine oil.
(1) Insert Filter/Regulator into the opening in the
fuel pump module, align the two hold down tabs with
the flange.
(2) While applying downward pressure, rotate the
Filter/Regulator clockwise until the the spring tab
engages the locating slot (Fig. 17).
(3) Connect the fuel line to the Filter/Regulator.
(4) Lower vehicle from hoist.
Fig. 15 Fuel Tank Locknut
1 ± SPECIAL TOOL 6856
2 ± LOCKNUT
Fig. 16 Locking Spring Tab
1 ± FUEL FILTER/PRESSURE REGULATOR
2 ± SPRING TAB
3 ± LOCATING SLOT
Fig. 17 Spring Tab In Locating Slot
1 ± FUEL FILTER/PRESSURE REGULATOR
2 ± SPRING TAB
3 ± LOCATING SLOT
PLFUEL SYSTEM 14 - 13
REMOVAL AND INSTALLATION (Continued)

FUEL PUMP INLET STRAINER
REMOVAL
(1) Remove fuel pump module. Refer to Fuel Pump
Module Removal in this section.
(2) Using a thin straight blade screwdriver, pry
back the locking tabs on fuel pump reservoir and
remove the strainer (Fig. 18).
(3) Remove strainer O-ring from the fuel pump
reservoir body.
(4) Remove any contaminants in the fuel tank by
washing the inside of the fuel tank.
INSTALLATION
(1) Lubricate the strainer O-ring with clean engine
oil.
(2) Insert strainer O-ring into outlet of strainer so
that it sits evenly on the step inside the outlet.
(3) Push strainer onto the inlet of the fuel pump
reservoir body. Make sure the locking tabs on the
reservoir body lock over the locking tangs on the
strainer.
(4) Install fuel pump module. Refer to Fuel Pump
Module Installation in this section.
FUEL LEVEL SENSOR
REMOVAL
Remove fuel pump module. Refer to Fuel Pump
Module in this section.
(1) Depress retaining tab and remove the fuel
pump/level sensor connector from the bottom of the
fuel pump module electrical connector (Fig. 19).
(2) Pull off blue locking wedge (Fig. 20).
(3) Using a small screwdriver lift locking finger
away from terminal and push terminal out of connec-
tor (Fig. 21).(4) Push level sensor signal and ground terminals
out of the connector (Fig. 22).
(5) Insert a screwdriver between the fuel pump
module and the top of the level sensor housing (Fig.
23). Push level sensor down slightly.
(6) Slide level sensor wires through opening fuel
pump module (Fig. 24).
(7) Slide level sensor out of installation channel in
module.
INSTALLATION
(1) Insert level sensor wires into bottom of opening
in module.
(2) Wrap wires into groove in back of level sensor
(Fig. 23).
Fig. 18 Inlet Strainer Removal
1±TABS
2 ± INLET STRAINER
Fig. 19 Fuel Pump/Level Sensor Electrical
Connector
1 ± RETAINING TAB
2 ± TANK SEAL
3 ± ELECTRICAL CONNECTOR
Fig. 20 Wire Terminal Locking Wedge
1 ± ELECTRICAL CONNECTOR
2 ± BLUE LOCKING WEDGE
14 - 14 FUEL SYSTEMPL
REMOVAL AND INSTALLATION (Continued)

(3) While feeding wires into guide grooves, slide
level sensor up into channel until it snaps into place
(Fig. 24). Ensure tab at bottom of sensor locks in
place.(4) Install level sensor wires in connector. Push
the wires up through the connector and then pull
them down until they lock in place. Ensure signal
and ground wires are installed in the correct posi-
tion.
(5) Install locking wedge on connector.
(6) Push connector up into bottom of fuel pump
module electrical connector.
(7) Install fuel pump module. Refer to Fuel Pump
Module in this section.
FUEL INJECTORS
REMOVAL
(1) Disconnect negative cable from battery.
(2) Release fuel system pressure. Refer to Fuel
System Pressure Release procedure in this section.
(3) Disconnect fuel supply tube from rail. Refer to
Quick-Connect Fittings in the Fuel Delivery section
of this group.
(4) Disconnect electrical connectors from fuel injec-
tors (Fig. 25), refer to the fuel injector connector sec-
tion for electrical connector removal.
(5) Remove fuel rail mounting screws.
(6) Lift rail off of intake manifold. Cover the fuel
injector openings in the intake manifold.
(7) Remove fuel injector retainer (Fig. 26).
(8) Pull injector out of fuel rail. Replace fuel injec-
tor O-rings (Fig. 27).
INSTALLATION
(1) Apply a light coating of clean engine oil to the
upper O-ring.
(2) Install injector in cup on fuel rail.
Fig. 21 Wire Terminal Locking Finger
1 ± LOCKING FINGER
2 ± WIRE TERMINAL
Fig. 22 Removing Wires From Connector
1 ± LOCKING FINGER
2 ± WIRE TERMINAL
Fig. 23 Loosening Level Sensor
1 ± FUEL LEVEL SENSOR
2 ± CHANNEL FOR LEVEL SENSOR
Fig. 24 Level Sensor Removal/Installation
1 ± REAR VIEW OF LEVEL SENSOR
2 ± LEVEL SENSOR
3 ± WRAP WIRES IN GROOVE
4 ± CHANNEL FOR LEVEL SENSOR
PLFUEL SYSTEM 14 - 15
REMOVAL AND INSTALLATION (Continued)

(3) Install retaining clip.
(4) Apply a light coating of clean engine oil to the
O-ring on the nozzle end of each injector.
(5) Insert fuel injector nozzles into openings in
intake manifold. Seat the injectors in place. Tighten
fuel rail mounting screws to 22.5 N´m63 N´m
(200630 in. lbs.).
(6) Attach electrical connectors to fuel injectors,
refer to the fuel injector connector section for electri-
cal connector installation.
(7) Connect fuel supply tube to fuel rail. Refer to
Quick Connect Fittings in the Fuel Delivery Section
of this Group.
FUEL TANK
REMOVAL
(1) Disconnect the negative battery cable (Fig. 28).
(2) Perform fuel system pressure release, refer to
the fuel system pressure release procedure in this
section.
(3) Raise and support vehicle on hoist.
(4) Disconnect vapor line from EVAP canister tube.
(5) Remove EVAP canister (Fig. 29).
(6) Drain fuel tank. Remove the drain port cap and
remove fuel. Drain fuel tank into holding tank or a
properly labeledGasolinesafety container. Reinstall
drain port cap when done draining fuel (Fig. 30).
Fig. 25 Fuel Rail and Injectors
1 ± FUEL SUPPLY LINE
2 ± FUEL LINE QUICK-CONNECTS
3 ± IGNITION COIL
4 ± FUEL RAIL
5 ± FUEL INJECTOR
Fig. 26 Fuel Injector Retainer
1 ± RETAINER
2 ± FUEL RAIL
3 ± FUEL INJECTOR
Fig. 27 Fuel Injector O-Rings
1 ± FUEL INJECTOR
2 ± NOZZLE
3 ± TOP (FUEL ENTRY)
Fig. 28 Battery Cable
14 - 16 FUEL SYSTEMPL
REMOVAL AND INSTALLATION (Continued)