Chrysler Caravan/Voyager/Town n Country 1984-1995

Fuel Fittings

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REMOVAL & INSTALLATION



See Figures 1 and 2



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Fig. Fig. 1: Servicing the fuel fittings-1987-90 2.5L engines



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Fig. Fig. 2: Servicing the fuel fittings-1991-95 2.5L engines

  1. Remove air cleaner assembly.
  2.  
  3. Perform fuel system pressure release.
  4.  
  5. Disconnect negative battery cable.
  6.  
  7. On 1991-95 models, loosen the fuel tube clamp on the valve cover.
  8.  
  9. On 1987-90 models, loosen fuel intake and return hose clamps. On 1991-95 models remove the fuel tubes from the quick-disconnect fittings. Wrap a shop towel around each hose, twist and pull off each hose.
  10.  
  11. Remove each fitting and note inlet diameter. Remove copper washers.
  12.  

To install:
  1. Replace copper washers with new washers.
  2.  
  3. Install fuel fittings in proper ports and tighten to 15 ft. lbs. (20 Nm).
  4.  
  5. On 1987-90 models, using new original equipment type hose clamps, install fuel return and supply hoses.
  6.  
  7. On 1991-95 models, Lubricate the ends of the fuel tubes with 30 weight oil. Insert the tubes into the quick-disconnect fittings and pull to make sure they are securely locked.
  8.  
  9. On 1991-95 models, tighten the fuel tube clamp on the valve cover.
  10.  
  11. Reconnect negative battery cable.
  12.  
  13. Test for leaks using ATM tester C-4805 or equivalent. With ignition in the RUN position depress ATM button. This will activate pump and pressurize the system. Check for leaks.
  14.  
  15. Reinstall the air cleaner assembly.
  16.  

 
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