Chrysler Front Wheel Drive Cars 6-CYL 1988-1995 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



Except Premier and Monaco

See Figures 1, 2, 3 and 4


CAUTION
Fuel injected engines use high pressure in their operation. 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 bled the pressurized fuel from the system. Failure to do this could readily cause a fire or injury.

  1. Disconnect the negative battery cable from the battery.
  2.  
  3. Relieve fuel system pressure as follows:
    1. Loosen the fuel filler cap to release fuel tank pressure.
    2.  
    3. Locate and unplug the fuel rail electrical injector harness connector from the engine harness.
    4.  
    5. Connect a jumper wire from terminal No. 1 of the appropriate 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.  
    9. On all vehicles except the TC, repeat the procedure for 2 or 3 of the fuel injectors. The TC does not require doing this to several injectors; one is enough.

      Click image to see an enlarged view

      Fig. Fig. 1: Fuel injector harness connector for all except Premier, Monaco or TC by Maserati cars



      Click image to see an enlarged view

      Fig. Fig. 2: Fuel injector harness connector for the TC by Maserati cars

    10.  

  4.  
  5. The fuel filter is mounted under the vehicle, next to the fuel tank. Raise and support the rear of the vehicle safely on jackstands.
  6.  
  7. Remove the retaining screw that mounts the filter to its retaining bracket so you can reach the hose clamps.
  8.  
  9. Then, loosen the clamps (quick-connect fittings on later cars-see the procedures for the fittings in Fuel System ) 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.
  10.  
  11. 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. Replace the filter, draining fuel into a metal container and disposing of it safely. Inspect the hoses and clamps and replace defective parts as necessary.
  12.  



Click image to see an enlarged view

Fig. Fig. 3: Before removing the fuel filter, note the positions of the two fuel lines and refer to Section 5 for information about the Quick-Connect fittings-excpet Premier, Monaco and TC by Maserati vehicles



Click image to see an enlarged view

Fig. Fig. 4: On the TC by Maserati cars, make certain the correct fuel lines are attached to the right fuel filter nipples

For vehicles not equipped with Quick-Connect fittings, Chrysler uses and recommends hoses that meet their specifications and are labeled "EFM/EFI 18519''. Make sure you use either this type of hose or an equivalent, high pressure one, rated up to 55 psi (379 kPa). Be sure not to use ordinary rubber fuel hose, as this is not tough enough for high pressure use and may not be able to resist the destruction caused by certain types of contamination. Also, if 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 high clamping forces required for 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:
  1. Reconnect the hoses, using the proper routing noted as you disconnected them. For the older rubber hoses, you may want to very slightly wet the inside diameter of the hoses to make it easier to install them onto the filter connections. Install them 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. If you have an inch lb. torque wrench, tighten them to 10 inch lbs. (1 Nm).
  2.  
  3. Connect the quick-connect hoses, if so equipped.
  4.  
  5. Remount the filter on the bracket and tighten the bolt to 6 ft. lbs. (8 Nm). Start the engine and check for leaks, tightening the hose clamps, replacing parts, or installing the hoses farther onto the connectors (older hose types), if necessary. Allow the engine a little while to start, since the fuel system must be pressurized.
  6.  

Premier and Monaco

See Figure 5


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 reconnect 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.  



Click image to see an enlarged view

Fig. Fig. 5: The Premier and Monaco vehicles also have Quick-Connect type fuel line fittings-refer to Section 5 before removing the fuel lines

To install:
  1. Carefully remove the retainers from the fuel filter nipples with a thin straight blade tool. 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 to 9 ft. lbs. (12 Nm).
  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, turn the key to the ON position to pressurize the fuel system and check for leaks.
  10.  

 
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