Chrysler Full-Size Trucks 1989-1996 Repair Guide

Fuel Filter

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REMOVAL & INSTALLATION




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

All 1989-93 Gasoline Engines and 1994-96 2.5L Engines

See Figure 1

The fuel filter is located in the fuel line on the inside of the left frame rail, just ahead of the crossmember.



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Fig. Fig. 1: Fuel filter location for gasoline engines

  1. Relieve the fuel system pressure as described in Fuel System .
  2.  
  3. Unfasten the filter retaining screw and remove the filter from the frame rail.
  4.  
  5. Wrap a shop towel around the hose connections to catch fuel spillage. Loosen the fuel hose clamps and disconnect the hoses from the filter.
  6.  
  7. Remove the old fuel filter and replace it with a new one.
  8.  
  9. Connect the fuel hoses and tighten the hose clamps. Position the filter on the frame rail and tighten the retaining screw to 75 inch lbs. (8 Nm).
  10.  

1994-96 Gasoline Engines-Except 2.5L

See Figures 2, 3 and 4

The fuel filter is integrated into the fuel pressure regulator which is mounted in the fuel tank. This unit is not controlled by the PCM or engine vacuum. It is calibrated to deliver approximately 35-45 psi (241-310 kPa) of fuel pressure to the injectors. If the pressure exceeds the maximum of the specified range, an internal diaphragm closes to route fuel back into the fuel tank. This system eliminates the need for conventional return lines from the engine bay and accounts for the name of the "Returnless'' fuel injection system employed in these vehicles.

Fuel tank removal is required for this procedure. Also needed will be external snapring pliers and proper hose clamp pliers, such as No. C-4124 pliers (available through Plymouth/Dodge dealers), or equivalent.

  1. Relieve the fuel system pressure as described in Fuel System .
  2.  



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Fig. Fig. 2: With the fuel tank removed, twist and pull the fuel filter/regulator for removal from the rubber mounting grommet

  1. Drain the fuel tank and remove the tank.
  2.  
  3. Remove the fuel filter/regulator (which is pressed into a rubber grommet) by twisting and pulling it straight up.
  4.  



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Fig. Fig. 3: Use snapring pliers to remove the retainer securing the cover tube to the base of the filter/regulator

  1. Remove the snapring retaining the cover tube, then slide it down to reveal the clear plastic fuel tube and its retaining clamp.
  2.  



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Fig. Fig. 4: Cut off the old tube clamp without damaging the plastic fuel tube

  1. Gently cut off the old clamp without damaging the tube, then discard the clamp.
  2.  
  3. Carefully pull the tube off, then remove the filter/regulator from the fuel pump module.
  4.  

To install:
  1. Install a new clamp over the plastic fuel tube and attach it loosely to the filter/regulator. Rotate the unit in the line until it is pointed to the driver's side of the vehicle.
  2.  
  3. Tighten the clamp using hose clamp pliers such as No. C-4124 (available through the Plymouth/Dodge dealer).
  4.  

Do not use conventional side cutters to tighten the clamp.

  1. Slide the cover tube up to the bottom of the filter/regulator and install the snapring.
  2.  
  3. Carefully press the assembly back into the rubber grommet by hand. It should be pointed to the driver's side of the vehicle.
  4.  
  5. Install the fuel tank.
  6.  

 
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