Chrysler Full-Size Vans 1989-1998 Repair Guide

Quick-Connect Fuel Fittings

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REMOVAL & INSTALLATION



Single-Tab Type

See Figure 1


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  1. Remove the engine cover.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Clean the fitting of any foreign material before disassembly.
  10.  
  11. Press the release tab on the side of the fitting to release the pull tab.
  12.  


WARNING
The release tab must be pressed prior to releasing the pull tab or the tab will be damaged.

  1. While pressing the release tab on the side of the fitting, use a small prytool to pry up the pull tab.
  2.  
  3. Raise the pull tab until it separates from the quick-disconnect fitting. Discard the old pull tab.
  4.  
  5. Disconnect the quick-connect fitting.
  6.  
  7. Inspect the fitting body and the fuel system component for damage. Replace as necessary.
  8.  

To install:
  1. Insert the quick-connect fitting into the fuel tube or component until the built-on stop on the fuel tube or component rests against the back of the fitting.
  2.  
  3. Obtain a new pull tab. Push the new tab down until it locks into place in the quick-connect fitting.
  4.  
  5. Pull firmly on the fitting to verify the fitting is secure.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Start the engine and check for leaks.
  10.  
  11. Install the air cleaner assembly.
  12.  
  13. Install the engine cover.
  14.  



Click image to see an enlarged view

Fig. Fig. 1: Disengaged view of a single-tab style quick-connect fitting

Two-Tab Type

See Figures 2 and 3


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  1. Remove the engine cover.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Clean the fitting of any foreign material before disassembly.
  10.  
  11. Squeeze the plastic retaining tabs against the sides of the fitting with your fingers.
  12.  
  13. Pull the fitting from the component or tube being disconnected. The plastic retainer will stay on the component or tube. The O-rings and spacer will remain in the fitting connector body.
  14.  
  15. Inspect the fitting body and the fuel system component for damage. Replace as necessary.
  16.  

To install:
  1. Insert the quick-connect fitting to the component or fuel tube and into the plastic retainer. When a connection is made, a click will be heard.
  2.  
  3. Pull firmly on the fitting to verify the fitting is secure.
  4.  
  5. Connect the negative battery cable.
  6.  
  7. Start the engine and check for leaks.
  8.  
  9. Install the air cleaner assembly.
  10.  
  11. Install the engine cover.
  12.  



Click image to see an enlarged view

Fig. Fig. 2: Remove the fuel line connection by pressing down on its tabs (arrows) and pulling the line outward



Click image to see an enlarged view

Fig. Fig. 3: Assembled view of the two-tab style quick-connect fitting

Plastic Retainer Ring Type

See Figure 4


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  1. Remove the engine cover.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Clean the fitting of any foreign material before disassembly.
  10.  
  11. To release the fitting, firmly push the fitting towards the component it's attached to while firmly pushing the plastic retainer ring into the fitting.
  12.  
  13. Pull the fitting from the component or tube being disconnected. The plastic retainer will stay on the component or tube.
  14.  
  15. Inspect the fitting body and the fuel system component for damage. Replace as necessary.
  16.  

To install:
  1. Insert the quick-connect fitting to the component or fuel tube and into the plastic retainer. When a connection is made, a click will be heard.
  2.  
  3. Pull firmly on the fitting to verify the fitting is secure.
  4.  
  5. Connect the negative battery cable.
  6.  
  7. Start the engine and check for leaks.
  8.  
  9. Install the air cleaner assembly.
  10.  
  11. Install the engine cover.
  12.  



Click image to see an enlarged view

Fig. Fig. 4: Plastic retainer ring type fuel fitting

Latch Clip Type

See Figures 5 and 6


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  1. Remove the engine cover.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Clean the fitting of any foreign material before disassembly.
  10.  
  11. Pry up on the latch clip with a screwdriver and remove the clip from the quick-connect fitting.
  12.  
  13. Insert a proper fuel line removal tool, available from such companies as Lisle, into the fuel line.
  14.  
  15. With the tool inserted inside the line releasing the locking fingers, pull the line releasing the connection.
  16.  
  17. Inspect the fitting, locking fingers and fuel line for damage, repair as necessary.
  18.  

To install:
  1. Insert the fitting end onto the line or component until a click is heard.
  2.  
  3. Pull firmly on the fitting to verify the fitting is secure.
  4.  
  5. Install the latch clip onto the fitting.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Start the engine and check for leaks.
  10.  
  11. Install the air cleaner assembly.
  12.  
  13. Install the engine cover.
  14.  



Click image to see an enlarged view

Fig. Fig. 5: Use a screwdriver to carefully remove the latch



Click image to see an enlarged view

Fig. Fig. 6: A special tool is required to disengage this type of connection

 
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