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

Fuel Filter

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

REMOVAL & INSTALLATION



Carbureted Engines

See Figures 1, 2, 3, 4 and 5

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Fig. Fig. 1: Engine compartment fuel line routing and fuel filter mounting location-2.2L carbureted engines



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Fig. Fig. 2: Engine compartment fuel line routing and fuel filter mounting location-2.6L engines



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Fig. Fig. 3: Some carbureted 2.6L engines are also equipped with a filter-reservoir unit



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Fig. Fig. 4: When installing the new filter, make certain to connect the hoses to the correct filter nipples-2.2L carbureted engines



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Fig. Fig. 5: The fuel filter on 2.6L engines is not equipped with a third outlet for venting fumes back to the fuel tank

There are two fuel filters in the carbureted system. One is part of the gauge unit assembly located inside the fuel tank on the suction end of the tube. This filter normally does not need servicing, but may be replaced or cleaned if a very large amount of extremely coarse material gets into the tank and clogs it.

The 2.2L engine uses a disposable filter-vapor separator that is located on the front side of the engine block between the fuel pump and carburetor. On some applications, this filter has not only inlet and outlet connections, but a third connection designed to permit fuel to return to the tank so that vapor, which accumulates in hot weather, will not interfere with carburetion.

The 2.6L engine uses a disposable, canister type filter. This type of filter has only two connections. A few models equipped with 2.6L engines use a filter-reservoir assembly that attaches to the air cleaner and also has three connections, one for the elimination of vapor.

A plugged fuel filter can limit the speed at which a vehicle can be driven and may cause hard starting. The most critical symptom will usually be suddenly reduced engine performance at maximum engine power levels, as when passing.

Remove the filter as follows:

  1. Have a metal container ready to catch spilled fuel. Make sure the engine is cool.
  2.  


CAUTION
Never work on the fuel system when the engine is still warm-residual heat could cause fuel vapors to explode.

  1. Remove the hose clamps from each end of the filter. Then, disconnect the hoses and collect the fuel in the metal container.
  2.  
  3. Remove the old filter and hoses. On the non-return (two connection) type filter used on 2.6 liter engines, this requires unfastening the mounting bracket. On the reservoir type filter, remove the two mounting nuts inside the air cleaner.
  4.  

To install:
  1. Hold the new filter in position. If it has mounting studs, pass them through the mounting bracket and then install the attaching nuts until snug.
  2.  
  3. Connect the hoses, then install and tighten the hose clamps (if the hoses are difficult to install onto the nipples, you can wet the inside of the hose very slightly). Make sure the clamps are located approximately 1 / 4 in. (6mm) from the ends of the hoses. The hose clamps should also be installed so that they are situated on the inside of the nipples' bulges (located on the ends of the filter connections).
  4.  
  5. Start the engine and check for fuel leaks.
  6.  

Fuel Injected Engines
EXCEPT PREMIER

See Figures 6, 7, 8, 9, 10 and 11

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Fig. Fig. 6: When relieving the fuel system pressure, make sure to attach the jumper wires to the correct injector harness connector terminals, as shown



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Fig. Fig. 7: Screw-type hose clamps were used on the fuel filter on 1984-87 fuel injected vehicles



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Fig. Fig. 8: Vehicles manufactured from 1988-95 utilize special quick-disconnect fittings on the fuel system hoses



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Fig. Fig. 9: The fuel filter is mounted under the car, next to the fuel tank-first remove the mounting bolt ...



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Fig. Fig. 10: ... then lower the fuel filter from its mounting and ...



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Fig. Fig. 11: ... disconnect the fuel lines from the filter-fuel injected engines, except Premier


CAUTION
Fuel injected engines utilize high pressures in their fuel systems. This pressure is maintained through the action of check valves even when the engine is off. Therefore, you must be sure to work on the fuel carrying parts of injected cars only when the engine has cooled off and only after you have properly relieved the pressure from the fuel system. Failure to do this could cause fire or personal injury.

  1. For 1981-88 models, relieve the fuel system pressure as follows:
    1. Loosen the fuel tank cap to release any accumulated air pressure that may be there. Then, disconnect the electrical connector at the single fuel injector on the throttle body on cars with throttle body injection. On cars with multi-point injection, disconnect the electrical connector on the injector closest to the battery.
    2.  
    3. Use a jumper wire to ground one of the injector terminals for whichever injector you've disconnected.
    4.  
    5. Connect one end of a jumper wire to the other injector terminal. Then, just touch the other end of the second jumper to the battery positive post for nearly 10 seconds.
    6.  

  2.  

Make sure you do not maintain this connection for more than a maximum of 10 seconds, otherwise the injector will be damaged.

  1. For 1989-95 models, relieve fuel system pressure as follows:
    1. Loosen the fuel filler cap to release fuel tank pressure.
    2.  
    3. Locate and disconnect the fuel injector harness connector at the edge of the throttle body.
    4.  
    5. Connect a jumper wire from terminal No. 1 of the fuel injector wiring harness connector to a good ground.
    6.  
    7. Being careful not to allow contact between the jumper leads, connect a jumper wire to terminal No. 2 of the connector and touch the other end of the jumper to the positive battery post for no longer than 5 seconds. This will relieve fuel pressure.
    8.  

  2.  

The fuel filter is mounted in the rear of the car onto the vehicle body rail next to the fuel tank.

  1. Remove the retaining screw that mounts the filter to its retaining bracket so you can reach the hose clamps.
  2.  

For 1991-95 models, refer to Fuel System for procedures concerning the quick-disconnect type fuel lines.

  1. Loosen the clamps for both the inlet and outlet lines. Quickly wrap a shop towel around these connections to collect escaping fuel safely. Then, dispose of this towel in such a way as to protect it from heat and the chance of fire.
  2.  
  3. Note the routing of the hoses. The high pressure hose from the tank and pump goes to the inlet connection, which is always located toward the outer edge of the filter. The outlet hose to the engine is labeled on some filters and is always at the center. Pull the hoses off the connections on the filter.
  4.  

  1. Replace the filter, draining fuel into a metal container and disposing of it safely. Inspect the hoses and clamps-replace defective parts as necessary.
  2.  

Chrysler uses and recommends hoses that meet their specifications and are labeled "EFM/EFI18519''. Make sure you use either this type of hose or an equivalent, high pressure-up to 55 psi (379 kPa) type of fuel hose available in the automotive aftermarket. Do not use ordinary rubber fuel hose, as this is not strong enough for high pressure use and may not be able to resist the destruction caused by certain types of contamination. Also on vehicles utilizing hose clamps, if the hose clamps require replacement, note that the original equipment clamps have rolled edges to keep the edge of the band from cutting into the hose, due to the necessary use of high clamping forces with a high pressure fuel system. Make sure that you use either an original equipment clamp or a similar type of clamp available in the aftermarket.

To install:

For 1991-95 models, refer to Fuel System for procedures concerning the quick-disconnect type fuel lines.

  1. Reconnect the hoses, using the proper routing noted earlier. On 1981-87 models, you may want to very slightly wet the inside diameter of the hoses to make it easier to install them onto the filter connections. Slide them onto the filter connections as far as possible, until they are well over the bulges at the ends of the connectors. Install the clamps so they are a short distance away from the ends of the hoses but well over the bulged areas at the ends of the filter connections. Tighten both clamps securely.
  2.  
  3. Install the filter on the bracket with the mounting screw.
  4.  
  5. Start the engine and check for leaks.
  6.  

PREMIER

See Figure 12

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Fig. Fig. 12: The Premier utilizes unique quick-disconnect fittings, unlike any of the other late-model vehicles covered by this information


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

  1. Relieve the fuel pressure as follows:
    1. Loosen the fuel filler cap to release fuel tank pressure.
    2.  
    3. Disconnect the fuel pump harness connector located in the rear of the vehicle near the fuel tank.
    4.  
    5. Start the vehicle and allow it to run until it stalls from lack of fuel. Turn the key to the OFF position.
    6.  
    7. Disconnect the negative battery cable, then reattach the fuel pump connector.
    8.  
    9. Wrap shop towels around the fitting that is being disconnected to absorb residual fuel in the lines.
    10.  

  2.  
  3. The filter is located on the frame rail near the rear of the vehicle. Depress, or squeeze the retainer tabs together and slowly pull the connectors from the fuel filter. Note the retainer tabs stay on the fuel filter nipples.
  4.  
  5. Remove the screw holding the fuel filter in place and remove the filter.
  6.  

To install:
  1. Carefully remove the retainers from the fuel filter nipples with a thin, straight-bladed prytool. Insert the tool between the filter nipple and the wedge portion of the retainer that seats against the shoulder of the nipple. Press the wedge back and slip the wedge over the nipple shoulder. Repeat this on the other side of the retainer and then pull the retainer off the nipple.
  2.  
  3. Push the retainers back into the fuel line quick-connect fittings. Ensure that the locking ears and the shoulder (stop bead) on the fuel tube are completely visible in the windows on the side of the quick-connect fitting.
  4.  
  5. The fuel filter may be marked IN and OUT at the nipple ends. The side marked IN is connected to the fuel line from the fuel tank. The side of the filter marked OUT is connected to the fuel line that runs to the engine. After determining the proper direction, install the fuel filter with the attaching screw.
  6.  
  7. Use a clean cloth to wipe the tube ends clean and lightly lubricate the fuel tube ends with clean 30 weight motor oil. The connectors contain O-rings which do not have to be replaced when the fittings are disconnected. Push the quick-connect fitting over the fuel tube until a click is heard. If the quick-connect fitting is the type that has windows on the side, ensure that the locking ears on the retainer and the shoulder (stop bead) on the fuel tube are completely visible in the windows. Do not rely on the audible click to confirm that a secure connection has been made. Pull back on the quick-connect fitting to further ensure that the connection is complete and the connector is locked in place.
  8.  
  9. Connect the negative battery cable, install the fuel filler cap and turn the key to the ON position to pressurize the fuel system.
  10.  
  11. Check the fuel system for leaks.
  12.  

 
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