Chrysler Caravan/Voyager/Town n Country 1984-1995

Mechanical Fuel Pump

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See Figures 1, 2, 3 and 4



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Fig. Fig. 1: Fuel pump installation-2.2L engines



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Fig. Fig. 2: Removing the fuel pump blocker strut retaining bolt



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Fig. Fig. 3: Removing the fuel pump blocker strut



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Fig. Fig. 4: The fuel pump removed from the engine. Oil filter removed for illustration purposes

The 2.2L and 2.6L engine use a mechanical type fuel pump located on the side of the engine. The fuel pump is driven by an eccentric cam which is cast on the accessory drive shaft.

REMOVAL & INSTALLATION




CAUTION
Do not smoke when working around gasoline, cleaning solvent or other flammable substances.

  1. Remove the oil filter.
  2.  
  3. Disconnect the fuel lines from the pump.
  4.  
  5. Plug the lines to prevent fuel leakage.
  6.  
  7. Remove the fuel pump blocker strut from front engine mount-to-blocker assembly.
  8.  
  9. Remove the fuel pump mounting bolts.
  10.  

To install:
  1. Clean all gasket material from engine block mounting surface and spacer block.
  2.  
  3. Assemble the new gaskets and spacer block to fuel pump.
  4.  
  5. Install the fuel pump mounting bolts in pump mounting flange.
  6.  
  7. Position the pump assembly on engine block and tighten bolts alternately to 21 ft. lbs. (28 Nm).
  8.  
  9. Connect the fuel lines to the pump.
  10.  
  11. Position the fuel pump blocker strut on blocker assembly and front engine mount. Tighten assembly.
  12.  
  13. Install the oil filter. Check and adjust oil level.
  14.  
  15. Start the engine and check fuel fittings for leaks.
  16.  

TESTING




CAUTION
Never smoke when working around gasoline! Avoid all sources of sparks or ignition. Gasoline vapors are EXTREMELY volatile!

Volume Test

The fuel pump should supply 1 qt. (0.946 l) of fuel in 1 minute or less at idle.

Pressure Test
  1. Insert a T-fitting in the fuel line at the carburetor.
  2.  
  3. Connect a six inch piece of hose between the T-fitting and a pressure gauge. A longer piece of hose will result in an inaccurate reading.
  4.  
  5. Disconnect the inlet line to the carburetor at the fuel pump and vent the pump. Failure to vent the pump will result in low pressure reading. Reconnect the fuel line.
  6.  
  7. Connect a tachometer to the engine. Start the engine and allow to idle. The pressure gauge should show a constant 4.5-6 psi (31-41 kPa) reading. When the engine is turned OFF , the pressure should slowly drop to zero. An instant drop to zero indicates a leaky diaphragm or weak spring. If pressure is too high, the main spring is too strong or the air vent is plugged.
  8.  
  9. Proceed with the vacuum test.
  10.  

Vacuum Test
  1. Remove the inlet and outlet fuel lines from the pump.
  2.  
  3. Plug the fuel line to the carburetor to prevent fuel leakage.
  4.  
  5. Connect a vacuum gauge to the fuel pump inlet fitting.
  6.  
  7. Using the starter motor, turn the engine over several times and observe the vacuum gauge. The fuel pump should develop a minimum of 11 in. Hg (37 kPa) of vacuum.
  8.  
  9. If the vacuum readings are below specification, replace the pump.
  10.  

 
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