Chrysler New Yorker. Manual — part 259
(7) Raise tank into position and install tank
straps.
(8) Install the fuel filler tube and tighten the
clamp.
(9) Reposition the stabilizer bar and install bolts.
(10) Lower vehicle.
(11) Connect the fuel pump electrical connector
that is in the rear seat.
(12) Install the rear seat.
(13) Connect the battery cable.
(14) Fill fuel tank. Use the DRB scan tool to pres-
surize the fuel system. Check for leaks.
FUEL PUMP INLET STRAINER
REMOVAL
(1) Remove fuel pump module. Refer to Fuel Pump
Module Removal in this section.
(2) Using a thin straight blade screwdriver, pry
back the locking tabs on fuel pump reservoir and
remove the strainer (Fig. 13).
(3) Remove strainer O-ring from the fuel pump
reservoir body.
(4) Remove any contaminants in the fuel tank by
washing the inside of the fuel tank.
INSTALLATION
(1) Lubricate the strainer O-ring with clean engine
oil.
(2) Insert strainer O-ring into outlet of strainer so
that it sits evenly on the step inside the outlet.
(3) Push strainer onto the inlet of the fuel pump
reservoir body. Make sure the locking tabs on the
reservoir body lock over the locking tangs on the
strainer.
(4) Install fuel pump module. Refer to Fuel Pump
Module Installation in this section.
FUEL LEVEL SENSOR
REMOVAL
Remove fuel pump module. Refer to Fuel Pump
Module in this section.
(1) Depress the retaining tab and remove the fuel
pump/level sensor connector from the bottom of the
fuel pump module electrical connector (Fig. 14).
(2) Remove wire terminal retaining clip from con-
nector (Fig. 15). Note the location of terminals for the
level sensor wires (Fig. 16).
Fig. 13 Inlet Strainer Removal
Fig. 14 Fuel Pump/Level Sensor Connector
Fig. 15 Wire Terminal Retaining Clip
300M
FUEL SYSTEM
14 - 11
REMOVAL AND INSTALLATION (Continued)
(3) Using special tool 7812 or an equivalent, push
level sensor signal and ground terminals out of the
connector (Fig. 17).
(4) Insert a screwdriver between the fuel pump
module and the top of the level sensor housing (Fig.
18). Push level sensor down slightly.
(5) Slide level sensor wires through standpipe
inside fuel pump module (Fig. 19).
(6) Slide level sensor out of installation channel
(Fig. 18).
INSTALLATION
(1) Insert level sensor wires in bottom of stand-
pipe.
(2) Wrap wires into groove in back of level sensor
(Fig. 20).
(3) While feeding wires into standpipe, slide level
sensor up into installation channel until it snaps into
place. Ensure tab at bottom of sensor locks in place.
(4) Install level sensor wires in connector. Push
the wires up through the connector and then pull
them down until they lock in place. Ensure signal
and ground wires are installed in the correct position
(Fig. 16).
(5) Install retaining clip on connector.
Fig. 16 Wire Terminal Identification
Fig. 17 Level Sensor Signal and Ground Wires
Fig. 18 Fuel Level Sensor Removal
Fig. 19 Standpipe Inside Module
Fig. 20 Level Sensor Installation
14 - 12
FUEL SYSTEM
300M
REMOVAL AND INSTALLATION (Continued)
(6) Push fuel pump/level sensor connector up into
bottom of fuel pump module electrical connector.
(7) Install fuel pump module. Refer to Fuel Pump
Module in this section.
FUEL RAIL—2.7L ENGINE
WARNING:
RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL RAIL. SERVICE VEHI-
CLES IN WELL VENTILATED AREAS AND AVOID
IGNITION SOURCES. NEVER SMOKE WHILE SER-
VICING THE VEHICLE.
REMOVAL
(1) Release fuel system pressure. Refer to Fuel
System Pressure Release Procedure in this section.
(2) Disconnect negative battery cable.
(3) Remove intake manifold plenum. Refer to
Group 11, Exhaust System and Intake Manifold for
intake removal.
(4) Remove intake manifold plenum mounting
bolts. Lift Plenum up off of engine. Cover intake
manifold to prevent foreign material from entering
engine.
(5) Disconnect fuel supply tube quick connect fit-
tings at the rear of intake manifold. Refer to Quick
Connect Fittings in the Fuel Delivery Section of this
Group.
(6) If the injector connectors are not tagged with
their cylinder number, tag them to identify the cor-
rect cylinder.
(7) Remove fuel rail mounting bolts.
(8) Lift fuel rail straight up off of cylinder head.
(9) Remove retaining clips from fuel injectors at
fuel rail.
(10) Remove fuel injector from fuel rail.
INSTALLATION
(1) Lightly lubricate the fuel injector O-rings with
a couple drops of clean engine oil.
(2) Install retaining clips on fuel injectors.
(3) Push injectors into fuel injector rail until clips
are in the correct position.
(4) Position fuel rail over cylinder heads, and push
rail into place. Tighten fuel rail mounting bolts to 11
N·m (100 in. lbs.) torque.
(5) Install intake manifold plenum. Refer to Group
11, Exhaust System and Intake Manifold for intake
installation.
(6) Connect negative cable to battery.
FUEL RAIL—3.2/3.5L ENGINE
REMOVAL
WARNING:
RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL RAIL. SERVICE VEHI-
CLES IN WELL VENTILATED AREAS AND AVOID
IGNITION SOURCES. NEVER SMOKE WHILE SER-
VICING THE VEHICLE.
(1) Release fuel system pressure. Refer to Fuel
System Pressure Release Procedure in this section.
(2) Disconnect the negative battery cable.
(3) Remove intake manifold plenum. Refer to
Group 11, Exhaust System and Intake Manifold for
intake removal.
(4) Remove intake manifold plenum mounting
bolts. Lift Plenum up off of engine. Cover intake
manifold to prevent foreign material from entering
engine.
(5) Disconnect fuel supply tube quick connect fit-
ting at the rear of the fuel rail.
(6) If the injector connectors are not tagged with
their cylinder number, tag them to identify the cor-
rect cylinder (Fig. 21).
(7) Remove mounting bolts on both sides of fuel
rail.
(8) Lift fuel rail straight up off of cylinder head.
(9) Remove retaining clips from fuel injectors at
fuel rail.
(10) Remove fuel injector from fuel rail.
INSTALLATION
(1) Lightly lubricate the fuel injector O-rings with
a couple drops of clean engine oil.
(2) Install retaining clips on fuel injectors.
(3) Push injectors into fuel injector rail until clips
are in the correct position.
(4) Position fuel rail over cylinder heads, and push
rail into place. Tighten fuel rail mounting bolts to 11
N·m (100 in. lbs.) torque.
Fig. 21 Injector Electrical Connectors
300M
FUEL SYSTEM
14 - 13
REMOVAL AND INSTALLATION (Continued)
(5) Install intake manifold plenum. Refer to Group
11, Exhaust System and Intake Manifold for intake
installation.
(6) Connect negative cable to battery.
FUEL INJECTORS—2.7L ENGINE
WARNING:
RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL RAIL. SERVICE VEHI-
CLES IN WELL VENTILATED AREAS AND AVOID
IGNITION SOURCES. NEVER SMOKE WHILE SER-
VICING THE VEHICLE.
REMOVAL
(1) Release fuel system pressure. Refer to Fuel
System Pressure Release Procedure in this section.
(2) Disconnect negative cable to battery.
(3) Remove intake manifold plenum. Refer to
Group 11, Exhaust System and Intake Manifold for
intake removal.
(4) Remove intake manifold plenum mounting
bolts. Lift Plenum up off of engine. Cover intake
manifold to prevent foreign material from entering
engine.
(5) Disconnect fuel supply tube quick connect fit-
tings at the rear of intake manifold. Refer to Quick
Connect Fittings in the Fuel Delivery Section of this
Group.
(6) If the injector connectors are not tagged with
their cylinder number, tag them to identify the cor-
rect cylinder.
(7) Remove electrical connectors from the fuel
injectors.
(8) Remove fuel rail mounting bolts.
(9) Lift fuel rail straight up off of the cylinder
head.
(10) Remove retaining clips from fuel injectors at
fuel rail.
(11) Remove fuel injectors.
INSTALLATION
(1) Lightly lubricate the fuel injector O-rings with
a couple drops of clean engine oil.
(2) Install fuel injectors.
(3) Install retaining clips on fuel injectors.
(4) Push injectors into fuel injector rail until clips
are in the correct position.
(5) Position fuel rail over cylinder head, and push
rail into place. Tighten fuel rail mounting bolts to 11
N·m (100 in. lbs.) torque.
(6) Connect fuel supply tube quick connect fittings
at the rear of intake manifold. Refer to Quick Con-
nect Fittings in the Fuel Delivery Section of this
Group.
(7) Connect electrical connectors to fuel injectors.
(8) Install intake manifold plenum. Refer to Group
11, Exhaust System and Intake Manifold for intake
installation.
(9) Connect negative cable to battery.
FUEL INJECTORS—3.2/3.5L ENGINE
WARNING:
RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL RAIL. SERVICE VEHI-
CLES IN WELL VENTILATED AREAS AND AVOID
IGNITION SOURCES. NEVER SMOKE WHILE SER-
VICING THE VEHICLE.
REMOVAL
(1) Release fuel system pressure. Refer to Fuel
System Pressure Release Procedure in this section.
(2) Disconnect the negative battery cable.
(3) Remove intake manifold plenum. Refer to
Group 11, Exhaust System and Intake Manifold for
intake removal.
(4) Remove intake manifold plenum mounting
bolts. Lift Plenum up off of engine. Cover intake
manifold to prevent foreign material from entering
engine.
(5) Disconnect fuel supply tube quick connect fit-
tings at the rear of intake manifold. Refer to Quick
Connect Fittings in the Fuel Delivery Section of this
Group.
(6) If the injector connectors are not tagged with
their cylinder number, tag them to identify the cor-
rect cylinder (Fig. 21).
(7) Remove electrical connectors from the fuel
injectors.
(8) Remove mounting bolts on both sides of fuel
rail.
(9) Lift fuel rail straight up off of cylinder head.
(10) Remove retaining clips from fuel injectors at
fuel rail.
(11) Remove fuel injectors.
INSTALLATION
(1) Lightly lubricate the fuel injector O-rings with
a couple drops of clean engine oil.
(2) Install retaining clips on fuel injectors.
(3) Push injectors into fuel injector rail until clips
are in the correct position.
(4) Position fuel rail over cylinder head, and push
rail into place. Tighten fuel rail mounting bolts to 11
N·m (100 in. lbs.) torque.
(5) Connect fuel supply tube quick connect fittings
at the rear of intake manifold. Refer to Quick Con-
nect Fittings in the Fuel Delivery Section of this
Group.
(6) Connect electrical connectors to fuel injectors.
14 - 14
FUEL SYSTEM
300M
REMOVAL AND INSTALLATION (Continued)
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