Chrysler Front Wheel Drive Cars 6-CYL 1988-1995 Repair Information

Tank Assembly

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REMOVAL & INSTALLATION




CAUTION
Service vehicles in a well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle.

Except Premier and Monaco

See Figures 1, 2, 3 and 4

  1. Remove the fuel filler cap and properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Loosen the lug nuts on the right rear wheel, then raise and support the rear of the vehicle using jackstands.
  6.  
  7. Remove the rubber cap from the drain tube. The tube is located on the rear of the fuel tank. Connect either a portable holding tank or a siphon hose to the drain tube.
  8.  
  9. Drain the fuel tank into a holding tank or a properly labeled gasoline safety container.
  10.  
  11. Remove the fuel filler tube-to-quarter panel screws.
  12.  
  13. Remove the right rear tire and wheel assembly.
  14.  


CAUTION
Keep rags handy to wipe any gasoline which may be spilled during separation of the various fuel lines and tubes.



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Fig. Fig. 1: Unplug the electrical wiring harness connectors from the fuel pump and sending unit ...



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Fig. Fig. 2: ... and make sure that the connectors are clean for better electrical contact



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Fig. Fig. 3: Use a ratchet wrench and socket for ease and speed when loosening the fuel tank strap bolt

  1. Unplug the pump and sending unit wire connectors.
  2.  
  3. Disconnect the fuel supply and return hoses from the fuel pump. Refer to the procedures describing fuel line removal earlier in this section.
  4.  
  5. Support the fuel tank with a transmission jack. Loosen the mounting straps and lower the tank slightly. Remove the hose from the pressure relief/rollover valve.
  6.  
  7. Carefully work the fuel filler tube from the tank.
  8.  
  9. Remove the tank mounting straps and lower the tank.
  10.  

To install:
  1. Position the tank on the transmission jack. Connect the vapor separator/rollover valve hose and place the insulator pad on the fuel tank. Position the vapor vent so it will not be pinched between the tank and floor pan.
  2.  
  3. Raise the tank and fuel filter tube carefully into position. Use a light coating of power steering fluid to ease the fuel filler tube installation. Ensure that the filler tube grommet is not damaged. Verify that the tube is installed correctly.
  4.  



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Fig. Fig. 4: Common fuel tank assembly

  1. Make sure the straps are not twisted or bend, then tighten the fuel tank strap nuts to 17 ft. lbs. (23 Nm). Remove the transmission jack.
  2.  
  3. Lubricate the metal tubes on the fuel pump with clean SAE 30 weight engine oil. Install the quick-connect fuel fittings. Refer to the fuel fitting procedures located earlier in this section.
  4.  
  5. Attach the electrical connector to the fuel pump module and level sensor unit.
  6.  
  7. Install the rear wheel and tighten the lug nuts until snug.
  8.  
  9. Lower the vehicle.
  10.  
  11. Tighten the lug nuts on the right rear wheel.
  12.  
  13. Attach the filler tube to the filler neck opening in the quarter panel. Tighten the quarter panel screws to 17 inch lbs. (2 Nm).
  14.  
  15. Fill the fuel tank, install the filler cap, and connect the battery cable.
  16.  
  17. Start the vehicle and check for fuel leaks.
  18.  

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

Premier and Monaco

See Figures 5, 6, 7 and 8

  1. Disconnect the battery negative cable.
  2.  
  3. Remove the fuel filler cap.
  4.  
  5. Using a portable gasoline siphon/storage tank, drain the fuel tank until completely empty.
  6.  
  7. Slightly loosen the lug nuts on the right rear wheel.
  8.  
  9. Raise the rear of the vehicle and safely support with jackstands.
  10.  
  11. Remove the right rear tire and wheel.
  12.  
  13. Remove the splash shield from under the wheel well.
  14.  
  15. Remove the ground wire retaining nut.
  16.  
  17. Loosen the hose clamp and disconnect the fuel tank vent hose from the fuel tank filler neck.
  18.  
  19. Slide the fuel tank vent hose out of the clip on the frame.
  20.  



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Fig. Fig. 5: Ground wire and vent hose positions



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Fig. Fig. 6: Fuel tank strap and nut tightening dimensions

  1. Loosen and remove both nuts securing the fuel tank support strap. Push the other end of the strap up and out the left side frame rail.
  2.  
  3. Place a transmission jack or similar jacking device under the fuel tank to support it while removing the tank.
  4.  

The black colored tube is the fuel supply line and the gray colored tube is the return line.


CAUTION
The fuel supply system may be pressurized. Have shop towels handy to absorb any spilled fuel when separating the quick-connect fitting. Wear eye protection in case of spraying gasoline. Extinguish all smoking devices when servicing the fuel tank.

  1. Using a clean, lint-free cloth, wipe the quick-connect fittings clean of dirt and/or road salt. Spray compressed air around the fittings to remove any loosened dirt or road salt. Separate the quick-connect fittings by squeezing the retainer tabs and pulling the fitting back. The quick-connect retainer will stay on the nipple.
  2.  
  3. Disconnect the fuel supply tube from the fuel filter. Pull the fuel supply tube through the access hole in the frame.
  4.  



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Fig. Fig. 7: Fuel tube and electrical wire connections



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Fig. Fig. 8: Fuel tank assembly

  1. Detach the fuel pump/sending unit electrical connector.
  2.  
  3. Disconnect the fuel vapor hose and fuel return tube.
  4.  
  5. Remove the fuel tank mounting bolts.
  6.  
  7. Lower the fuel tank 2-3 in. (51-76mm) on the transmission or equivalent jack.
  8.  


WARNING
When lowering the fuel tank on the transmission jack, it is necessary to tip the rear of the tank down to allow the two mounting flanges to slide out from above the rear axle. Support the tank so that it does not fall from the jack.

  1. Push the fuel tank vent hose towards the fuel tank through the access hole in the frame.
  2.  
  3. Lower the tank and remove it from the jack.
  4.  

To install:
  1. Center the fuel tank on the transmission jack, or equivalent.
  2.  
  3. Raise the jack until the fuel tank is 8-10 in. (20-25cm) below the vehicle.
  4.  
  5. Tip the front of the fuel tank up over the rear axle and continue raising the tank until it is 1-2 in. (25-51mm) away from its installed position.
  6.  
  7. Route the fuel tank filler vent hose through the access hole in the frame.
  8.  
  9. Continue raising the tank into place.
  10.  
  11. Install the fuel tank mounting bolts. Tighten the bolts to 12 ft. lbs. (16 Nm).
  12.  
  13. Remove the transmission jack.
  14.  
  15. Install the fuel tank support strap. Tighten the top nut until the distance between the bottom of the strap bolt and the strap is 2.1-2.4 in. (54-60mm).
  16.  
  17. Push the black fuel supply hose through the hole in the body.
  18.  

Before connecting any fuel tubes, read the quick-connect procedures located earlier in this section.

  1. Fasten the fuel supply quick-connect fitting at the fuel filter and the in-line fitting in the gray fuel return line.
  2.  
  3. Attach the fuel pump module electrical connector.
  4.  
  5. Connect the fuel vapor hose.
  6.  
  7. Attach the fuel vent hose to the fuel tank filler neck. Secure with the hose clamp. Route the hose through the clip on the body.
  8.  
  9. Install the ground wire with the retaining nut.
  10.  
  11. Install the splash shield in the wheelwell.
  12.  
  13. Install the rear tire and wheel. Tighten the wheel lug nuts to 63 ft. lbs. (85 Nm).
  14.  
  15. Lower the vehicle.
  16.  
  17. Fill the fuel tank with fuel, then install the fuel tank filler cap.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Start the vehicle and check for fuel leaks.
  22.  

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

SENDING UNIT REPLACEMENT



Except Premier and Monaco

See Figure 9

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the fuel tank assembly, as previously detailed.
  4.  
  5. Using a hammer/mallet and brass (or the equivalent non-metallic) punch carefully tap the lockring counterclockwise to loosen the sending unit assembly.
  6.  
  7. Lift the sending unit and O-ring away from the tank assembly.
  8.  



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Fig. Fig. 9: Use a brass punch and hammer or mallet to loosen (counterclockwise) the retaining ring

To install:
  1. Wipe the seal area of the tank assembly clean and place a new O-ring seal in the proper position.
  2.  
  3. Inspect the internal fuel line hose and its attachment to the reservoir. Ensure that the internal fuel return line does not interfere with the sending unit float travel.
  4.  
  5. Install the sending unit in the tank assembly and position the lockring in position. Using the brass drift and mallet, tap the lockring in a clockwise direction.
  6.  
  7. Install the tank assembly in the vehicle.
  8.  
  9. Attach the negative battery cable.
  10.  

Early Premier and Monaco

See Figures 10 through 17

If you are not sure whether your Premier or Monaco is designated as an early or late model, please refer to the model differentiation portion.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the fuel tank, as described earlier in this section.
  4.  
  5. Separate the quick-connect fittings of the black fuel supply line 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.  



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Fig. Fig. 10: Disconnect the fuel supply and return hoses from the fuel pump/sender unit-early Premier and Monaco



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Fig. Fig. 11: The retainers will stay on the nipples once the fuel lines have been removed-early Premier and Monaco

  1. Remove the bolts that hold the fuel pump/sender unit face plate to the fuel tank.
  2.  
  3. 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.
  4.  
  5. If the fuel pump is working fine, but the sending unit needs to be replaced with a new one, remove the fuel pump from the old sending unit and install into the new one. Remove the fuel pump from the sending unit as follows:
    1. Disconnect the wires from the terminal on top of the fuel pump.
    2.  
    3. Unscrew the fuel pump lower support bracket nut. Remove the fuel pump support bracket, gasket and bolt.
    4.  
    5. Disconnect the hose clamp at the inlet port of the fuel pump.
    6.  
    7. Unscrew the hose clamp and pull the fuel pump out. Keep the gasket for installation.

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      Fig. Fig. 12: It may be necessary to move the unit back and forth to clear all of the components when removing it from the fuel tank-early Premier and Monaco



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      Fig. Fig. 13: Save the old gasket (if not damaged) or obtain a new one for reinstallation-early Premier and Monaco

    8.  

  6.  
  7. Once the fuel pump has been removed, the sending unit can be replaced with a new one.
  8.  

To install:
  1. If the old fuel pump is to be reused in the new sending unit, install it to the sending unit as follows:
    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.

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      Fig. Fig. 14: Fuel pump wire connections on the sending unit/fuel pump assembly-early Premier and Monaco



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      Fig. Fig. 15: Fuel pump lower support bracket-early Premier and Monaco

    8.  

  2.  
  3. 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.
  4.  
  5. Position the gasket so that the holes in the gasket line up with the bolt holes in the fuel tank.
  6.  
  7. 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.
  8.  
  9. Screw the retaining bolts into the tank.
  10.  
  11. Attach the fuel tube quick-connect fittings to the nipples on the face plate, following the procedures located earlier in this section. The black fuel supply line goes to the larger nipple. The gray tube fuel return line goes to the smaller nipple.
  12.  
  13. Install the fuel tank.
  14.  



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Fig. Fig. 16: Fuel inlet port hose and fuel pump-early Premier and Monaco



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Fig. Fig. 17: Fuel pump components-early Premier and Monaco

  1. Connect the battery cable.
  2.  
  3. Start the vehicle and check for fuel leaks.
  4.  

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

Late Premier and Monaco

See Figures 18 and 19

If you are not sure whether your Premier or Monaco is designated as an early or late model, please refer to the model differentiation portion.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the fuel tank by referring to the applicable procedure earlier in this section.
  4.  
  5. Loosen the fuel pump module clamp.
  6.  
  7. Carefully lift the fuel pump/sender module from the fuel tank.
  8.  



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Fig. Fig. 18: Fuel pump/sender module wiring and fuel hose positioning



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Fig. Fig. 19: Fuel pump module clamp and screw

To install:
  1. Position the gasket on the fuel pump/sender module flange.
  2.  
  3. Lower the fuel pump/sender module into the fuel tank. Rotate the module so that all of the fuel and vapor tubes point to the right side of the fuel tank (when the tank is installed in the vehicle). Connect the fuel pump module.
  4.  
  5. Position the fuel pump module clamp and tighten securely.
  6.  
  7. Install the fuel tank.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Start the vehicle and check for fuel leaks.
  12.  

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

 
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