Chrysler Pacifica. Manual — part 728
SPECIAL TOOLS
FUEL
Test Kit, Fuel
Adapters, Fuel Pressure Test—6539 and/or 6631
LOCKRING REMOVER/INSTALLER #9340
Fuel Line Adapter 1/4
O2S (OXYGEN SENSOR) REMOVAL/INSTALLER-
C4907
Oxygen sensor tool
CS
FUEL DELIVERY
14 - 3
FUEL DELIVERY (Continued)
FUEL LEVEL SENDING UNIT /
SENSOR
REMOVAL
(1) Release the fuel pressure, refer to the Fuel
Pressure Release Procedure in this section.
(2) Disconnect negative battery cable.
(3) Remove fuel tank, (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL TANK - REMOVAL).
(4) Vacuum area before removing module lock ring.
(5) Disconnect vapor line and electrical connector.
(6) Module lock ring contact points (Fig. 1).
(7) Remove module lock ring (Fig. 2).
NOTE: Use a brass punch to remove the 1/4 turn
lock ring.
(8) Remove module top.
(9) Tip module on to it’s side to drain fuel from
reservoir in module.
(10) Drain fuel tank, use an approved gasoline
draining station.
(11) Disconnect electrical connector for fuel level
sending card.
(12) Remove fuel level sending card by prying on
locking tab and pulling card down toward bottom of
the pump module (Fig. 3).
(13) There are 2 locking tabs on sending card; one
on the front and one on back (Fig. 4).
Fig. 1 LOCKING RING CONTACT POINTS
Fig. 2 MODULE LOCKING RING
Fig. 3 SENDING CARD REMOVAL
Fig. 4 SENDING CARD LOCKING TABS
14 - 4
FUEL DELIVERY
CS
INSTALLATION
(1) Install fuel level sending card to module.
(2) Connect electrical connector for fuel level send-
ing card.
(3) Install module top to module (Fig. 5) and (Fig.
6).
(4) Install module into the tank with the level unit
towards rear of tank.
(5) Install a new seal onto the tank, making sure
seal is properly seated in tank groove.
(6) Install module lock ring.
NOTE: Use a brass punch to Install the 1/4 turn lock
ring. Make sure all 5 tabs are properly seated.
(7) Connect vapor line and electrical connector.
(8) Install fuel tank, (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL TANK - INSTALLA-
TION)
(9) Connect negative battery cable.
(10) Fill fuel tank. Use the scan tool to pressurize
the fuel system. Check for leaks.
FUEL PRESSURE REGULATOR
REMOVAL
NOTE: THE FUEL PRESSURE REGULATOR IS ON
THE PASSENGER SIDE OF THE FUEL TANK.
(1) Release the fuel pressure, refer to the Fuel
Pressure Release Procedure in this section.
(2) Disconnect negative battery cable.
(3) Remove fuel tank (Fig. 7), (Refer to 14 - FUEL
SYSTEM/FUEL
DELIVERY/FUEL
TANK
-
REMOVAL) .
(4) Vacuum area before removing module lock ring.
(5) Disconnect lines from top of the module.
Fig. 5 MODULE TOP ALIGNMENT PINS
Fig. 6 Alignment PINS IN PLACE
Fig. 7 FUEL TANK ASSEMBLY
CS
FUEL DELIVERY
14 - 5
FUEL LEVEL SENDING UNIT / SENSOR (Continued)
(6) Remove module lock ring (Fig. 8).
NOTE: Use a brass punch to remove the 1/4 turn
lock ring.
(7) Drain fuel tank, use an approved gasoline
draining station.
(8) Remove module from fuel tank.
(9) Remove wire from side of regulator, depressed
tab on the connector in order to remove the ground
wire (Fig. 9).
(10) Ground wire removed (Fig. 10).
(11) Use a socket to compress the 4 tabs that
retain regulator.
(12) Pry up regulator and remove regulator and
o-rings.
INSTALLATION
NOTE: The o-rings should be placed on the regula-
tor first, to prevent them from being rolled out of
position during regulator install.
(1) Lightly lubricate the O-rings with clean engine
oil and place them onto regulator.
(2) Push regulator down and into place.
(3) Install ground wire.
(4) Install module and gasket seal.
(5) Ensure seal is properly positioned in fuel tank
groove.
(6) Install the module lock ring (Fig. 11).
Fig. 8 LOCKING RING CONTACT POINTS
Fig. 9 REGULATOR GROUND REMOVAL
Fig. 10 GROUND REMOVED
Fig. 11 LOCKING RING CONTACT POINTS
14 - 6
FUEL DELIVERY
CS
FUEL PRESSURE REGULATOR (Continued)
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