Chrysler Full-Size Vans 1989-1998 Repair Guide

Fuel Pump

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TESTING



Refer to the preceding Fuel System Pressure testing procedure.

REMOVAL & INSTALLATION



See Figures 1 and 2


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. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and support vehicle.
  6.  
  7. Remove the fuel tank.
  8.  
  9. Remove the locknut and lift out the fuel pump module.
  10.  
  11. Perform the following if you need to remove the sending unit:
    1. Remove the sending unit attaching screws from the mounting bracket located on the drain tube.
    2.  
    3. Label disconnect the wires from the sending unit and remove the sending unit. of the reservoir.
    4.  

  12.  
  13. If you need to remove the in-tank filter (sock) perform the following:
    1. Pry the mounting tabs back and remove the in-tank fuel filter (sock).To install:
    2.  

  14.  
  15. If removed, press a new filter (sock) onto the pump.
  16.  
  17. If removed connect the wires to the new sending unit, and install the sending unit onto the pump.
  18.  
  19. Using a new gasket, position the fuel pump module into the tank.
  20.  
  21. Position the locknut over the fuel pump module, and tighten the locknut.
  22.  
  23. Install the fuel tank.
  24.  
  25. Lower the vehicle.
  26.  
  27. Connect the negative battery cable.
  28.  



Click image to see an enlarged view

Fig. Fig. 1: Top view of a fuel pump module, as mounted in the tank



Click image to see an enlarged view

Fig. Fig. 2: View of a typical MFI style fuel pump's components

 
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