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

Electric Fuel Pump

Print

REMOVAL & INSTALLATION



Except Premier and Monaco

See Figure 1

An electric fuel pump is used with fuel injection systems in order to provide higher and more uniform fuel pressures. It is located in the tank.

  1. Disconnect the battery, and then remove the fuel tank, as described at the end of this section.
  2.  
  3. With a hammer and non-metallic or brass punch, tap the fuel pump lock ring counterclockwise to release the pump.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Use a brass punch and mallet to loosen (counterclockwise) the retaining ring

To install:
  1. Wipe the seal area of the tank clean and install a new O-ring seal.
  2.  
  3. Replace the filter on the end of the pump with a new one if it appears to be clogged or damaged.
  4.  
  5. Position the pump in the tank and install the locking ring. Tighten the ring (clockwise) in the same general way in which you loosened it-with the punch and hammer. Do not overtighten it, as this can cause leakage.
  6.  
  7. Install the tank as described at the end of this section.
  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.

Early Premier and Monaco

See Figures 2 through 9

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 procedures presented at the end of this section.
  4.  
  5. Disconnect 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.  



Click image to see an enlarged view

Fig. Fig. 2: Disconnect the fuel supply and return hoses from the fuel pump/sender unit-early Premier and Monaco



Click image to see an enlarged view

Fig. Fig. 3: The retainers will stay on the nipples once the fuel lines have been removed-early Premier and Monaco



Click image to see an enlarged view

Fig. Fig. 4: 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



Click image to see an enlarged view

Fig. Fig. 5: Save the old gasket, if not damaged, or have a new replacement for reinstallation-early Premier and Monaco



Click image to see an enlarged view

Fig. Fig. 6: Fuel pump wire connections on the sending unit/fuel pump assembly-early Premier and Monaco



Click image to see an enlarged view

Fig. Fig. 7: Fuel pump lower support bracket-early Premier and Monaco



Click image to see an enlarged view

Fig. Fig. 8: Fuel inlet port hose and fuel pump-early Premier and Monaco



Click image to see an enlarged view

Fig. Fig. 9: Fuel pump components-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. Disconnect the wires from the terminal on top of the fuel pump.
  6.  
  7. Unscrew the fuel pump lower support bracket nut. Remove the fuel pump support bracket, gasket and bolt.
  8.  
  9. Disconnect the hose clamp at the inlet port of the fuel pump.
  10.  
  11. Unscrew the hose clamp and pull the fuel pump out. Keep the gasket for installation.
  12.  

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.

Late Premier and Monaco

See Figures 10 and 11

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 at the end of this section.
  4.  
  5. Loosen the fuel pump module clamp.
  6.  
  7. Carefully lift the fuel pump/sender module from the fuel tank.
  8.  



Click image to see an enlarged view

Fig. Fig. 10: Fuel pump/sender module wiring and fuel hose positioning-late Premier and Monaco



Click image to see an enlarged view

Fig. Fig. 11: Fuel pump module clamp and screw-late Premier and Monaco

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 tank is installed in the vehicle). Compress 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.

TESTING



Except Premier and Monaco

See Figures 12, 13 and 14

To perform this test, you will need a pressure gauge capable of reading pressures above 55 psi (379 kPa). The gauge must have a connection that will fit the fuel rail service valve. The gauge must be the equivalent of Chrysler pressure gauge No. C-4799 and the connector fitting compatible with pressure test adapter 6539. You may also need a T and the fittings necessary to connect the gauge into the fuel supply line at the tank, as well as a 2 gallon container suitable for collecting fuel.

  1. Release the fuel system pressure as described in General Information & Maintenance .
  2.  
  3. Disconnect and plug the vacuum line going to the fuel pressure regulator.
  4.  
  5. Remove fuel hose quick connector from the chassis line.
  6.  
  7. Install the adapter between the fuel supply hose and chassis fuel line assembly for the 3.0L engines or into the service port of the fuel rail for 3.3L and 3.8L engines.
  8.  
  9. Hold the gauge and have someone start the engine. Run the engine at idle speed in Neutral (manual transaxles) or Park (automatic transaxles).
  10.  


CAUTION
Exercise extreme caution while under the hood with the engine running. Keep clear of all moving belts, fans, exhaust manifolds, etc.

  1. Read the pressure. It should be 48 psi (330 kPa). If it is outside the range, take note of it.
  2.  
  3. Stop the engine.
  4.  



Click image to see an enlarged view

Fig. Fig. 12: Attach the special pressure gauge to the service port on the fuel injection rail-3.3L and 3.8L engines

  1. Once again depressurize the system, disconnect the gauge and replace the protective cover.
  2.  
  3. If the pressure was correct, the test is complete. If the pressure is below the range, proceed with the next step; if it is too high, skip to Step 13.
  4.  


WARNING
In the next step, note that fuel may drain from the lines as you disconnect them. Make sure all surrounding exhaust system parts are cool and that all sources of ignition are removed from the area. Collect fuel and dispose of it safely.

  1. Connect the gauge into the fuel supply line running between the tank and the filter which is located at the rear of the vehicle.
  2.  


WARNING
Make sure all connections are secure.

  1. Have an assistant start the engine, then read the pressure gauge. If the pressure has risen more than 5 psi (35 kPa), replace the filter. If the pressure is now within range, allow the engine to cool and remove all sources of ignition; depressurize the system; disconnect the gauge from the lines; replace the fuel filter; and restore all connections.
  2.  



Click image to see an enlarged view

Fig. Fig. 13: Fuel pressure gauge and adapter-3.0L engines, except Premier and Monaco



Click image to see an enlarged view

Fig. Fig. 14: Checking the fuel pump output pressure-3.0L engines, except Premier and Monaco

  1. If the pressure is still too low, gently and gradually pinch the fuel return line closed as you watch the gauge. If the pressure increases, the fuel pressure regulator is at fault. If there is no change, the problem is either clogging of the filter sock mounted on the pump or a defective pump itself.
  2.  
  3. If the pressure is too high, follow this procedure:
    1. Shut off the engine and allow it to cool.
    2.  
    3. Depressurize the fuel system, then disconnect the fuel return hose at the chassis, near the fuel tank.
    4.  
    5. Connect a 3 ft. (91cm) length of hose to the open end of the line running along the chassis. Position the open end of the line into a container suitable for collecting fuel.
    6.  
    7. Have a helper start the engine, then check the pressure again. If it is now correct, check the in-tank fuel return hose for kinking.
    8.  
    9. If the in-tank fuel return hose is okay, and the system still exhibits excessive pressure with the tank half full or more, the fuel pump reservoir check valve or aspirator jet may be obstructed and the assembly must be replaced.
    10.  

  4.  
  5. If the pressure is still too high, perform the following:
    1. Shut the engine OFF , and allow it to cool.
    2.  
    3. Depressurize the system once again and reconnect the fuel lines at the rear.
    4.  
    5. Disconnect the fuel return hose at the pressure regulator. Collect all fuel that drains.
    6.  
    7. Run the open connection into a large metal container.
    8.  
    9. Reconnect the fuel gauge to the fuel rail.
    10.  
    11. Start the engine and repeat the test. If the fuel pressure is now correct, clean a clogged return line or replace pinched or kinked sections of the return line. If no such problems exist, replace the fuel pressure regulator.
    12.  

  6.  

Premier and Monaco


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. Remove the fuel tank filler cap to relieve the fuel tank pressure.
  2.  

System fuel pressure will be released when disconnecting the fuel supply tube. Have shop towels handy to absorb spilled fuel.

  1. Use the quick disconnect tool 6182, or equivalent, to remove the black fuel supply tube from the fuel rail. Slide the tool over the nipple and up into the connector until the handle fits the connector. Pull the fuel supply tube off the fuel rail.
  2.  
  3. Install the fuel tube pressure adapter tool 6175, or equivalent.
  4.  
  5. Push the female end with the quick-connect fitting over the fuel rail until a click is heard. Pull the connector back to ensure that it is locked in place.
  6.  
  7. Push the male end with the nipple into the black fuel supply tube until a click is heard. Pull the nipple back to ensure that it is locked in place.
  8.  
  9. Attach a 0-60 psi (0-415 kPa) gauge from the fuel pressure test kit 5069, or equivalent, to the port on the fuel tube pressure adapter tool.
  10.  
  11. Start the engine and check the fuel pressure. It should be 28-30 psi (193-207 kPa) for early models and 43 psi (300 kPa) for late models. The fuel pressure regulator on these vehicles is non-adjustable.
  12.  
  13. If the fuel pressure is low, check for fuel flow through the return tube.
    1. If fuel is returning to the fuel tank through the fuel return tube, replace the fuel pressure regulator with a new one.
    2.  
    3. If the fuel is not returning to the fuel tank or just trickling out, inspect for a faulty fuel pump, possible clogged fuel filter or other restriction between the fuel pressure regulator and the fuel pump.
    4.  

  14.  
  15. If the fuel pressure is high, check the pressure regulator vacuum hose for leaks, and for a kink or restriction in the fuel return hose. If the pressure regulator vacuum hose is not leaking, the return tube is not kinked and does not have a restriction, the fuel pressure regulator should be replaced with a new one.
  16.  
  17. Remove the pressure gauge.
  18.  
  19. Disconnect the fuel tube pressure adapter tool with the quick disconnect tool.
  20.  
  21. Prior to installing the fuel tubes to the regulator and fuel rail the tube ends must be lightly lubricated with clean SAE 30 weight engine oil. Refer to the procedures describing the removal and installation of the fuel tubes.
  22.  
  23. Install the black fuel supply tube to the fuel rail and the gray fuel return tube to the pressure regulator.
  24.  
  25. Install the fuel tank filler cap.
  26.  
  27. Start the vehicle and check for fuel leaks.
  28.  

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

 
label.common.footer.alt.autozoneLogo