Chrysler Town, Dodge Caravan. Manual — part 341
FUEL DELIVERY
DESCRIPTION
DESCRIPTION
The front wheel drive car uses a plastic fuel tank
located rear center of the vehicle.
The Fuel Delivery System consists of: the following
items:
• Electric fuel pump module
• Fuel filter
• Tubes/lines/hoses
• Fuel injectors
The in-tank fuel pump module contains the fuel
pump. The pump is serviced as part of the fuel pump
module. Refer to Fuel Pump Module.
The fuel filter is replaceable only as part of the
fuel pump module.
DESCRIPTION - FFV REPLACEMENT PARTS
Many components in a Flexible Fuel Vehicle (FFV)
are designed to be compatible with ethanol. Always
be sure that the vehicle is serviced with correct etha-
nol compatible parts.
CAUTION: Replacing fuel system components with
non-ethanol compatible components can damage
your vehicle and may void the warranty.
OPERATION
The fuel system provides fuel pressure by an
in-tank pump module. The PCM controls the opera-
tion of the fuel system by providing battery voltage
to the fuel pump through the fuel pump relay. The
PCM requires only three inputs and a good ground to
operate the fuel pump relay. The three inputs are:
• Ignition voltage
• Crankshaft Position (CKP) sensor
• Camshaft Position (CMP) sensor
DIAGNOSIS AND TESTING - FUEL DELIVERY
SYSTEM
(Refer to Appropriate Diagnostic Information)
STANDARD PROCEDURE
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE PROCEDURE
(1) Remove Fuel Pump relay from Power Distribu-
tion Center (PDC). For location of relay, refer to label
on underside of PDC cover.
(2) Start and run engine until it stalls.
(3) Attempt restarting engine until it will no
longer run.
(4) Turn ignition key to OFF position.
(5) Return fuel pump relay to PDC.
(6) One or more Diagnostic Trouble Codes (DTC’s)
may have been stored in PCM memory due to fuel
pump relay removal. The DRB III
t scan tool must be
used to erase a DTC.
STANDARD PROCEDURE - DRAINING FUEL
TANK
Two different procedures may be used to drain fuel
tank (lowering tank or using DRB scan tool).
The quickest draining procedure involves lowering
the fuel tank.
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE.
As an alternative procedure, the electric fuel pump
may be activated allowing tank to be drained at fuel
rail connection. Refer to DRBIII
t scan tool for fuel
pump activation procedures. Before disconnecting
fuel line at fuel rail, release fuel pressure. Refer to
the Fuel System Pressure Release Procedure in this
group for procedures. Disconnect the fuel line at the
fuel rail and remove the plastic retainer from the
fuel rail. Take plastic retainer and install it back into
the fuel line from body. Attach end of special test
hose tool number 8978 at fuel line connection from
the body line. Position opposite end of this hose tool
to an approved gasoline draining station. Activate
fuel pump and drain tank until empty. When done
remove the special test hose tool number 8978 from
the body line. Remove the plastic retainer from the
special test hose tool number 8978 and reinstall it
into the fuel line from the body. Install the fuel line
to the fuel rail.
If electric fuel pump is not operating, tank must be
lowered for fuel draining. Refer to following proce-
dures.
(1) Remove fuel filler cap.
(2) Perform the Fuel System Pressure Release pro-
cedure.
(3) Disconnect negative cable from battery.
(4) Raise vehicle and support.
(5) Certain models are equipped with a separate
grounding wire (strap) connecting the fuel fill tube
assembly to the body. Disconnect wire by removing
screw.
(6) Open fuel fill door and remove screws mount-
ing fuel filler tube assembly to body. Do not discon-
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FUEL DELIVERY
RS
nect rubber fuel fill or vent hoses from tank at this
time.
(7) Place a transmission jack under center of fuel
tank. Apply a slight amount of pressure to fuel tank
with transmission jack.
(8) Remove fuel tank mounting strap nuts from
mounting strap studs.
(9) Lower the tank just enough so that the
filler tube fitting is the highest point of the fuel
tank.
(10) Remove filler tube from fuel tank. Tank will
be drained through this fitting.
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
(11) Drain fuel tank into holding tank or a prop-
erly labeled Gasoline safety container.
CAUTION: GASOLINE OR GASOLINE VAPORS ARE
HIGHLY FLAMMABLE. A FIRE COULD OCCUR IF AN
IGNITION SOURCE IS PRESENT. NEVER DRAIN OR
STORE GASOLINE OR DIESEL FUEL IN AN OPEN
CONTAINER, DUE TO THE POSSIBILITY OF FIRE
OR EXPLOSION.
(12) If fuel pump module removal is necessary,
refer to Fuel Pump Module Removal/Installation in
this section.
SPECIFICATIONS
FUEL SYSTEM PRESSURE
400 kpa ±34 kpa (58 psi ± 5 psi)
TORQUE
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Fuel Filler Neck Clamp
3.3
30
Fuel Rail 2.4L
22
200
Fuel Rail 3.3/3.8L
11.8
105
Fuel Tank Strap
54
40
Fuel Tank T Strap
28.2
250
Fuel Filter Bolt
4.5
40
SPECIAL TOOLS
FUEL
Pressure Gauge Assembly C–4799–B
Fuel Pressure Test Adapter 6539
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FUEL DELIVERY
14 - 3
FUEL DELIVERY (Continued)
FUEL FILTER
REMOVAL
(1) Release fuel pressure, refer to the Fuel release
procedure in this section.
(2) Disconnect the negative battery cable.
(3) Raise vehicle and support.
(4) Support the fuel tank with a transmission jack.
(5) Remove fuel line from the front of the tank.
(6) Remove ground strap
(7) Remove the inboard side of the fuel tank straps
and front T strap fastner.
(8) Lower the tank about 6 inches (Fig. 1).
(9) Remove fuel lines from the fuel pump module.
(10) Remove fuel filter from tank.
INSTALLATION
(1) Install fuel filter to tank. Tighten bolt to 4.5
N·m (40 in. lbs.)
(2) Install fuel lines to the fuel pump module (Fig.
1).
(3) Raise tank into position.
(4) Install the fuel tank straps.Tighten bolt for
main straps to 54 N·m (40 ft. lbs.) and the T strap
bolt to 28.2 N·m (250 in. lbs.)
(5) Install the ground strap
(6) Connect the fuel line at the front of the tank.
(7) Lower vehicle.
(8) Connect the negative battery cable.
(9) Pressurize the fuel system with the DRBIII
t
and check for leaks.
FUEL LEVEL SENDING UNIT /
SENSOR
DESCRIPTION
The fuel gauge level sending unit is attached to the
side of fuel pump module. The level sensor is a vari-
able resistor.
Spanner Wrench 6856
Fuel Line Adapter 1/4
O2S (Oxygen Sensor) Remover/Installer—C-4907
O2S (Oxygen Sensor) Remover/Installer - 8439
Fig. 1 FUEL FILTER
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FUEL DELIVERY
RS
FUEL DELIVERY (Continued)
OPERATION
Its resistance changes with the amount of fuel in
the tank. The float arm attached to the sensor moves
as the fuel level changes.
The fuel level input is used as an input for OBD II.
If the fuel level is below 15% or above 85% of total
tank capacity several monitors are disabled. There
are diagnostics for the level circuit open and shorted.
REMOVAL
Remove fuel pump module. Refer to Fuel Pump
Module in this section.
(1) Depress retaining tab and remove the fuel
pump/level sensor connector from the BOTTOM of
the fuel pump module electrical connector (Fig. 2) .
NOTE: The pump module harness on TOP of flange
is not serviceable or removable.
(2) Pull off the locking wedge.
(3) Using a small screwdriver lift locking finger
away from terminal and push terminal out of connec-
tor (Fig. 3) .
(4) Push level sensor signal and ground terminals
out of the connector (Fig. 4) .
(5) Insert a screwdriver between the fuel pump
module and the top of the level sensor housing (Fig.
5) . Push level sensor down slightly.
(6) Slide level sensor wires through opening fuel
pump module (Fig. 6) .
(7) Slide level sensor out of installation channel in
module.
INSTALLATION
(1) Insert level sensor wires into bottom of opening
in module.
Fig. 2 Fuel Pump/Level Sensor Electrical Connector
1 - ELECTRICAL CONNECTOR
2 - RETAINING TAB
Fig. 3 Wire Terminal Locking Finger
1 - LOCKING FINGER
2 - WIRE TERMINAL
Fig. 4 Removing Wires From
1 - FUEL PUMP FEED (RED B+)
2 - LEVEL SENSOR SIGNAL
3 - LEVEL SENSOR GROUND
4 - FUEL PUMP GROUND (BK)
Fig. 5 Loosening Level Sensor
1 - LEVEL SENSOR
2 - PRY DOWN ON LEVEL SENSOR
RS
FUEL DELIVERY
14 - 5
FUEL LEVEL SENDING UNIT / SENSOR (Continued)
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