Chrysler Front Wheel Drive Cars 4-CYL 1981-1995 Repair Information

Electric Fuel Pump

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REMOVAL & INSTALLATION



See Figures 1 through 9

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Fig. Fig. 1: Disconnect the fuel supply and return hoses from the fuel pump/sender unit



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Fig. Fig. 2: The retainers will stay on the nipples once the fuel lines have been removed



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Fig. Fig. 3: It may be necessary to move the unit back and forth to clear all of the components when removing it from the fuel tank



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Fig. Fig. 4: Save the old gasket, if not damaged, or have a new replacement for reinstallation



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Fig. Fig. 5: Fuel pump wire connections on the sending unit/fuel pump assembly



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Fig. Fig. 6: Fuel pump lower support bracket



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Fig. Fig. 7: Fuel inlet port hose and fuel pump



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Fig. Fig. 8: Fuel pump components



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Fig. Fig. 9: When the fuel lines are correctly attached, the ear will protrude through the window, as shown

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the fuel tank by referring to the procedures presented at the end of this section.
  4.  
  5. Disengage the quick-connect fittings of the black fuel supply tube and gray fuel return tube by squeezing the retainer tabs and pulling the connectors away from the nipples. The retainers will stay on the nipples.
  6.  
  7. Remove the bolts that hold the fuel pump/sender unit face plate to the fuel tank.
  8.  
  9. Carefully pull the fuel pump/sender unit out from the fuel tank. It will be necessary to tilt the unit forward and backward to allow the fuel filter and float arm room for removal. Note the position of the gasket for correct reassembly.
  10.  
  11. Disconnect the wires from the terminal on top of the fuel pump.
  12.  
  13. Unscrew the fuel pump lower support bracket nut. Remove the fuel pump support bracket, gasket and bolt.
  14.  
  15. Disconnect the hose clamp at the inlet port of the fuel pump.
  16.  
  17. Unscrew the hose clamp and pull the fuel pump out. Keep the gasket for installation.
  18.  

To install:
  1. Position the gasket on top of the fuel pump. Push the fuel pump up into the outlet hose and upper support bracket. Secure the hose to the fuel pump with the hose clamp.
  2.  
  3. Position the lower gasket and holding bracket at the bottom of the fuel pump. Install the bolt through the lower support bracket and rail. Tighten the nut and bolt securely.
  4.  
  5. Connect the hose to the inlet port of the fuel pump and secure with a hose clamp.
  6.  
  7. Install the electrical connectors to the terminals on the fuel pump.
  8.  
  9. There is a fuel reservoir (tray) in the bottom of the fuel tank that is contoured to hold the fuel filter. Be sure to install the fuel pump/sender unit so that the filter correctly fits into the tray.
  10.  
  11. Position the gasket so that the holes in the gasket line up with the bolt holes in the fuel tank.
  12.  
  13. Lower the fuel pump/sender unit into the fuel tank. It will be necessary to tilt the assembly backward and forward to provide clearance for the fuel filter and float arm.
  14.  
  15. Screw the retaining bolts into the tank.
  16.  
  17. Connect the fuel tube quick-connect fittings to the nipples on the face plate. Read the procedures for this located earlier in this section. The black fuel supply tube goes to the larger nipple. The gray tube fuel return tube goes to the smaller nipple.
  18.  
  19. Install the fuel tank.
  20.  
  21. Connect the battery cable.
  22.  
  23. Start the vehicle and check for fuel leaks.
  24.  

When starting the engine, allow extra time for the system to pressurize itself.

TESTING & ADJUSTMENT



See Figures 10 through 13



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Fig. Fig. 10: The fuel system pressure test port is located next to the fuel return tube



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Fig. Fig. 11: Fuel Pressure Test Fitting 6173 is needed to test the fuel system pressure-it installs into the test port on the throttle body



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Fig. Fig. 12: While the engine is idling, measure the amount of fuel system pressure-fuel pressure should be 14-15 psi (97-103 kPa)



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Fig. Fig. 13: Turn the adjusting screw to increase (clockwise) or decrease (counterclockwise) the amount of fuel pressure

The fuel pressure must be checked and, if necessary, adjusted whenever the fuel pressure regulator has been replaced.

Allow the engine to cool down before removing the test port plug. When removing the test port plug from the throttle body place shop towels around the port to catch fuel.

  1. Remove the throttle body bonnet.
  2.  

The throttle body is equipped with 2 port plugs on it. Fuel pressure is tested at the port on the side of the fuel pressure regulator next to the fuel return tube connection.

  1. Remove the fuel tank filler cap to release fuel tank pressure.
  2.  


CAUTION
Wear eye protection when servicing the fuel system. Do not smoke or allow open flame near fuel system components during fuel system service.

  1. Place shop towels around the throttle body. Slowly remove the test port plug from the throttle body. Catch spilled fuel with the shop rags.
  2.  
  3. Install Fuel Pressure Test Adapter 6173, or equivalent, into the test port.
  4.  
  5. Connect the 0-30 psi (0-207 kPa) Fuel Pressure Gauge from Fuel Gauge Set 5069, or equivalent, to the test fitting.
  6.  
  7. Start the engine and allow it to idle. Check the fuel pressure indicated on the pressure gauge. Fuel pressure should be 14-15 psi (97-103 kPa).
  8.  
  9. If the fuel pressure is not within specifications, adjust the fuel pressure regulator until the correct pressure is obtained. Adjust the regulator as follows:
    1. The fuel pressure regulator adjusting screw is located behind an aluminum plug in the nose of the fuel pressure regulator casing.
    2.  
    3. Remove the aluminum plug with a small punch and hammer. Lightly tap the plug until it pops out.
    4.  
    5. With the engine idling at 750-800 rpm, turn the adjustment screw until the fuel pressure is between 14-15 psi (97-103 kPa). Turning the screw clockwise increases the fuel pressure, whereas turning the screw counterclockwise decreases fuel system pressure.
    6.  

  10.  
  11. If the system is adequately adjusted, skip to Step 10.
  12.  
  13. If the fuel pressure is too low and cannot be adjusted to within specifications, there is a blockage in the fuel filter, supply line or there is a fuel pump malfunction. Replace the fuel filter and retest the system.
  14.  
  15. If the fuel system pressure is still too low, attach a fuel pressure gauge with a Tee between the fuel filter and the fuel pump. Measure the fuel pump pressure. If the fuel pump pressure is too low, replace the fuel pump, otherwise the fuel supply line needs to be replaced.the throttle body.
  16.  
  17. Disconnect the fuel gauge from the throttle body test port.
  18.  
  19. Remove the fuel pressure test adapter 6173 and install the plug into the test port.
  20.  
  21. Install the aluminum plug into the front of the regulator adjusting screw bore.
  22.  
  23. Install the throttle body bonnet.
  24.  

 
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