Chrysler Caravan/Voyager/Town and Country 1996-1999

Fuel Pump

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REMOVAL & INSTALLATION



See Figures 1 and 2

The in-tank fuel pump module contains the fuel pump and pressure regulator which adjusts fuel system pressure to approximately 49 psi. (338kPa). Voltage to the fuel pump is supplied through the fuel pump relay.

The fuel pump is serviced as part of the fuel pump module. The fuel pump module is installed in the top of the fuel tank and contains the electric fuel pump, fuel pump reservoir, inlet strainer, fuel gauge sending unit, fuel supply line and pressure regulator. The inlet strainer, fuel pressure regulator and level sensor are the only serviceable items. If the fuel pump requires service, replace the fuel pump module, using the following procedure:


CAUTION
The fuel injection system remains under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Remove the fuel filler cap and properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the fuel tank assembly from the vehicle.
  6.  


CAUTION
Observe all applicable safety precautions when working around fuel. Do not allow fuel spray or fuel vapors to come in contact with a spark or open flame. Keep a dry chemical (Class B) fire extinguisher near the work area. Never drain or store fuel in an open container due to the possibility of fire or explosion.

  1. Clean the top of the tank to remove any loose dirt.
  2.  



Click image to see an enlarged view

Fig. Fig. 1: Fuel pump module locknut removal



Click image to see an enlarged view

Fig. Fig. 2: Removing the fuel pump module from the fuel tank

  1. Using special tool No. 6856 or equivalent, remove the fuel pump locknut by turning it counterclockwise.
  2.  


CAUTION
The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed.

  1. Remove the fuel pump and O-ring from the tank. Discard the O-ring.
  2.  

To install:
  1. Thoroughly clean all parts. Wipe the seal area of the tank clean. Place a new O-ring in position on the pump module.
  2.  
  3. While holding the fuel pump module in place install the locking ring and tighten to 43 ft. lbs. (58 Nm) using special tool No. 6856 or equivalent spanner-type tool.
  4.  
  5. Install the fuel tank assembly.
  6.  
  7. Reconnect the negative battery cable.
  8.  
  9. Fill the fuel tank with fuel. Install the fuel filler cap. Turn the ignition switch to the ON position to pressurize the system. Check the fuel system for leaks.
  10.  

TESTING



Fuel system pressure testing requires the use of a DRB or equivalent scan tool.

The fuel pump operates at about 49 psi (338 kPa).

  1. Release the fuel system pressure, as outlined earlier in this section.
  2.  
  3. On all 4-cylinder models, remove the cap from the fuel pressure test port on the fuel rail and connect a suitable fuel pressure gauge.
  4.  
  5. On the 6-cylinder models, disconnect the fuel supply hose at the engine. Refer to the quick-connect fitting disengagement procedure earlier in this section. Install fuel pressure test adapter 6539, or equivalent, between the fuel rail and fuel line. Connect a suitable fuel pressure gauge to the test port on the adapter.
  6.  

When using the ASD fuel system test, the ASD relay and fuel pump relay remain energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the OFF position.

  1. Turn the ignition key to the ON position. Using the DRB or equivalent scan tool, access the ASD Fuel System Test. The ASD Fuel System Test will activate the fuel pump and pressurize the system. Note the gauge reading and compare with the following:

    If the gauge reading equals approximately 49 psi (338 kPa), no further testing is required. If the pressure is not correct, record the reading.
     
    If the fuel pressure is below specifications, check for a restricted fuel pump inlet strainer. If restricted, replace the inlet strainer. If not restricted, check for an incorrectly operating fuel filter, pressure regulator or fuel pump, and replace as necessary.
     
    If the fuel pressure is above specifications (54 psi or higher), check for a kinked or restricted fuel supply line. If the line is not kinked or restricted, check for a restriction in the chassis fuel supply line or for a kinked or plugged fuel supply line. If none of the lines are restricted, replace the fuel pressure regulator.
     

  2.  

 
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