Chrysler Cirrus/Stratus/Sebring/Avenger/Breeze 1995-1998

Fuel Pump

Print

REMOVAL & INSTALLATION



Sebring Coupe and Avenger

See Figures 1 and 2


CAUTION
Fuel injection systems remain 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.

Do not use conventional fuel filters, hoses or clamps when servicing fuel injection systems. They are not compatible with the injection system and could fail, causing personal injury or damage to the vehicle. Use only hoses and clamps specifically designed for fuel injection.

  1. Remove the fuel pump's access cover and relieve fuel system pressure, using the proper procedure as previously outlined. Be sure to leave both the negative battery cable and fuel pump harness disconnected.
  2.  

The rear seat cushion must be removed in order to gain access to the fuel pump.

Click image to see an enlarged view

Fig. Fig. 1: The fuel pump is under the far right access cover, while the fuel gauge unit is below the far left cover

  1. Disconnect the return hose and the high pressure fuel hose.
  2.  


CAUTION
Observe all applicable safety precautions when working around fuel. Do not allow fuel spray or fuel vapors to come into 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. Cover all fuel hose connections with a shop towel, prior to disconnecting, to prevent a splash of fuel that could be caused by residual pressure remaining in the fuel line.

  1. Remove the fuel pump mounting nuts and withdraw the pump assembly.
  2.  

To install:


Click image to see an enlarged view

Fig. Fig. 2: The seal position projections must be aligned with the holes in the fuel pump assembly

  1. Align the seal position projections with the holes in the fuel pump assembly and install the assembly in the tank. Tighten the retaining nuts to 22 inch lbs. (2.5 Nm).
  2.  
  3. Connect the high pressure hose, return hose and fuel pump wiring.
  4.  
  5. Connect the negative battery cable.
  6.  
  7. Check the fuel pump for proper pressure and inspect the entire system for leaks.
  8.  
  9. Apply sealant to the access cover and install the cover.
  10.  
  11. Install the rear seat cushion.
  12.  
  13. Pressurize the fuel system by turning the ignition key to the ON position. Check for leaks. Start the engine to verify proper fuel pump performance.
  14.  

Cirrus, Stratus, Sebring Convertible and Breeze

See Figures 3 and 4

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 and return line connections and the 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.


CAUTION
Fuel injection systems remain 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. Disconnect the negative battery cable from the left strut tower. The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.
  2.  
  3. Remove the fuel filler cap and relieve the fuel system pressure, as outlined earlier in this procedure.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Drain and remove the fuel tank, as outlined under the Tank Assembly removal and installation procedure, later in this section.
  8.  


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.  
  3. Disconnect the fuel lines from the fuel pump module by depressing the quick-connect retainers with your thumb and forefinger.
  4.  



Click image to see an enlarged view

Fig. Fig. 3: Removal of the fuel pump module lock ring using the special tool

  1. Using special tool 6856 (Fuel Pump Module Ring Spanner) or equivalent, remove the fuel pump lock ring.
  2.  


WARNING
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.



Click image to see an enlarged view

Fig. Fig. 4: Carefully remove the fuel pump module from the fuel tank

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

To install:
  1. Thoroughly clean all parts. Wipe the seal area of the tank clean. Place a new O-ring on the ledge between the tank threads and the pump module opening.
  2.  
  3. Position the fuel pump module in the tank. Make sure the alignment tab on the underside of the pump module flange sits in the corresponding notch in the fuel tank.
  4.  
  5. While holding the fuel pump module in place, install the locking ring and tighten to 45 ft. lbs. (61 Nm), using special tool 6856 or an equivalent spanner-type tool.
  6.  


WARNING
Do not overtighten the pump lock ring, as this may cause a fuel leak.

  1. Install a new fuel filter.
  2.  
  3. Raise and install the fuel tank assembly, as described later in this section.
  4.  
  5. Carefully lower the vehicle.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Refill the fuel tank with clean fuel. Turn the ignition switch to the ON position to pressurize the system. Check the fuel system for leaks.
  10.  

TESTING



Except Sebring Coupe and Avenger With 2.5L Engine

See Figures 5 and 6

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.  



Click image to see an enlarged view

Fig. Fig. 5: Checking the fuel pressure at the intake manifold-4-cylinder models



Click image to see an enlarged view

Fig. Fig. 6: Install the fuel pressure test adapter-6-cylinder models, except Sebring coupe and Avenger

  1. 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.
  2.  
  3. 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.
  4.  

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.  

Sebring Coupe and Avenger With 2.5L Engine

See Figures 7 through 13

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

  1. Release fuel system pressure as outlined earlier in this section.
  2.  
  3. On 1995 models, disconnect the high pressure fuel hose at the fuel rail side. On 1996-98 models, remove the fuel plate from the fuel rail.
  4.  



Click image to see an enlarged view

Fig. Fig. 7: Disconnect the high pressure fuel hose at the fuel rail-1995 models



Click image to see an enlarged view

Fig. Fig. 8: Remove the fuel plate from the fuel rail-1996-98 models


CAUTION
Cover the fuel plate or hose connection with a shop towel to absorb any fuel splash that could be caused by any residual pressure remaining in the fuel line.

  1. Remove the union joint and bolt from the adapter hose tool MD998709 or equivalent and connect special hose adapter tool MD998742 or equivalent to the adapter hose.
  2.  



Click image to see an enlarged view

Fig. Fig. 9: Fuel pressure gauge/adapter hose assembly

  1. Install a fuel pressure gauge to the adapter hose. Be sure to install a suitable O-ring or gasket between the fuel pressure gauge and adapter fitting to prevent any fuel leakage.
  2.  
  3. On 1995 models, install the fuel gauge/adapter hose assembly between the fuel rail and high pressure hose. On 1996-98 models, install the fuel gauge/adapter hose assembly between the fuel rail and fuel plate.
  4.  



Click image to see an enlarged view

Fig. Fig. 10: Installation of the fuel pressure gauge/adapter hose assembly

  1. Using the DRB, or equivalent scan tool, access the "Fuel System Test" to operate the fuel pump. Check for leaks in the fuel gauge and adapter hose assembly connections.
  2.  
  3. Start the engine and allow it to run at idle.
  4.  
  5. Measure the fuel pressure while the engine is running at idle. The pressure should read as follows:

    On 1995 models, the pressure should read 38 psi (265 kPa) with the fuel pressure regulator vacuum hose connected. With the vacuum hose disconnected and hose end blocked, the pressure should read 47-50 psi (324-343 kPa).
     
    On 1996-98 models, the pressure should read 47-50 psi (324-343 kPa).
     

  6.  



Click image to see an enlarged view

Fig. Fig. 11: Disconnect the vacuum hose from the fuel pressure regulator and plug with a finger-1995 models

  1. Race the engine several times and check that the fuel pressure at idle does not stop. On 1995 models, while racing the engine, hold the fuel return hose lightly with fingers to feel the presence of pressure in the return hose.
  2.  

If the fuel flow rate is low, there will be no pressure in the return hose.

  1. If any of the fuel pressure readings are out of specifications, refer to the troubleshooting chart.
  2.  



Click image to see an enlarged view

Fig. Fig. 12: Fuel pressure out-of-range troubleshooting chart

  1. Stop the engine and observe the fuel pressure gauge reading. It is normal if the reading does not drop within 2 minutes. If it does drop, observe the rate at which it does and refer to the troubleshooting chart.
  2.  



Click image to see an enlarged view

Fig. Fig. 13: Fuel pressure drop troubleshooting chart

  1. Release the residual pressure from the system and remove the fuel pressure gauge/adapter hose assembly.
  2.  


CAUTION
Cover the fuel plate or hose connection with a shop towel to absorb any fuel splash that could be caused by residual pressure remaining in the fuel line.

  1. On 1995 models, install the O-ring seal and connect the high pressure fuel hose. On 1996-98 models, install the fuel plate to the fuel rail. Install the retaining bolts and tighten to 43 inch lbs. (5 Nm).
  2.  

 
label.common.footer.alt.autozoneLogo