Chrysler Stratus Convertible. Manual — part 13
(10) Connect negative battery cable to battery or
auxiliary jumper terminal.
(11) Use the DRB scan tool ASD Fuel System Test
to pressurize the fuel system. Check for leaks.
REMOVAL AND INSTALLATION
AUTOMATIC SHUTDOWN RELAY
The relay is located in the Power Distribution Cen-
ter (PDC) (Fig. 10). For the location of the relay
within the PDC, refer to the PDC cover for location.
Check electrical terminals for corrosion and repair as
necessary.
FUEL PUMP RELAY
The fuel pump relay is located in the PDC. The
inside top of the PDC cover has a label showing relay
and fuse location.
FUEL PUMP MODULE
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.
REMOVAL
(1) Remove fuel filler cap and perform Fuel Sys-
tem Pressure Release procedure.
(2) Disconnect
negative
cable
from
auxiliary
jumper terminal.
(3) Remove fuel tank, refer to the Fuel Tank
removal section.
(4) Disconnect fuel filter lines from fuel pump
module.
(5) Clean top of tank to remove loose dirt and
debris.
(6) Using Special Tool #6856 Fuel Pump Module
Ring Spanner, remove locknut to release pump mod-
ule (Fig. 11).
WARNING:
THE FUEL RESERVOIR OF THE FUEL
PUMP MODULE DOES NOT EMPTY OUT WHEN THE
TANK IS DRAINED. THE FUEL IN THE RESERVOIR
MAY SPILL OUT WHEN THE MODULE IS REMOVED.
(7) Remove fuel pump module and O-ring from
tank (Fig. 12). Discard O-ring.
INSTALLATION
(1) Wipe seal area of tank clean. Place a new
O-ring on the ledge between the tank threads and
the pump module opening.
(2) Position fuel pump module in tank. Make sure
the alignment tab on the underside of the pump mod-
ule flange sits in the corresponding notch in the fuel
tank.
Fig. 10 Power Distribution Center (PDC)
1 – BATTERY POSITIVE
2 – BATTERY GROUND
3 – AIR CLEANER
4 – PCM
5 – PDC
6 – TCM
Fig. 11 Fuel Pump Module Locknut
1 – SPECIAL TOOL 6856
2 – FUEL PUMP MODULE LOCK RING
JX
FUEL SYSTEM
14 - 11
SERVICE PROCEDURES (Continued)
CAUTION: Over tightening the pump lock ring may
result in a leak.
(3) While holding the pump module in position,
install locknut. Tighten locknut to 74.5 N·m (55 ft.
lbs) torque using special tool #6856.
(4) Install fuel tank and fuel filter, refer to the
Fuel Tank installation section.
(5) Install negative cable to auxiliary jumper ter-
minal.
(6) Fill fuel tank with clean fuel. Use the DRB scan
tool to pressurize the system and check for leaks.
FUEL FILTER
The fuel filter mounts to the frame above the rear
of the fuel tank. The inlet and outlet tubes are per-
manently attached to the filter.
REMOVAL
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE DISCONNECTING QUICK- CONNECT FIT-
TINGS AT FUEL FILTER AND FUEL PUMP MODULE.
REFER TO THE FUEL PRESSURE RELEASE PRO-
CEDURE
(1) Remove rear seat.
(2) Disconnect fuel pump electrical connector. Push
grommet out and feed jumper completely through
hole in body.
(3) Remove fuel cap slowly to release tank pres-
sure.
(4) With vehicle on a hoist, drain fuel from tank.
Refer to Fuel Tank Draining in this section.
(5) Remove driver’s side fuel tank strap. Loosen, do
not remove, passenger side fuel tank strap allowing fuel
tank fill neck to touch rear suspension crossmember.
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
(6) Disconnect fuel lines from fuel pump module
(Fig. 13). These are quick connect fittings. Refer to
Quick Connect Fittings in this section.
(7) Disconnect fuel supply line from the fuel brake
module.
(8) Remove fuel filter (Fig. 14).
INSTALLATION
The fuel supply (to filter) tube, return tube (to
pump module) are permanently attached to the fuel
filter. The ends of the fuel supply and return tubes
have different size quick-connect fittings. The larger
quick-connect fitting connects to the large nipple
(supply side) on the fuel pump module. The smaller
quick-connect fitting attaches to the small nipple
(return side) on the fuel pump module.
(1) Apply a light coating of clean 30 weight engine
oil to the fuel filter nipples. Install fuel tubes. Refer
to Fuel Tubes and Quick-Connect Fittings in this sec-
tion.
(2) Install fuel tank, filter and tank straps, install
the front bolts first and then the rear bolts. Torque
tank strap bolts to 23 N·m (250. in. lbs.). Make sure
pump module harness grommet is installed in
body as tank is raised into position.
(3) Lower vehicle and connect pump module con-
nector.
(4) Install rear seat.
(5) Fill tank with fuel.
(6) Connect negative cable to auxiliary jumper ter-
minal.
Fig. 12 Fuel Pump Module Removal
1 – FUEL PUMP MODULE
2 – O-RING
Fig. 13 Fuel Lines at Fuel Pump Module
1 – FUEL LINES
2 – FUEL PUMP MODULE LOCK RING
3 – FUEL FILTER
14 - 12
FUEL SYSTEM
JX
REMOVAL AND INSTALLATION (Continued)
(7) Use the DRB scan tool ASD Fuel system test to
pressurize the the fuel system. Check for leaks.
FUEL PRESSURE REGULATOR
The fuel pressure regulator is part of the fuel
pump module (Fig. 15). Remove the fuel pump mod-
ule from the fuel tank to access the fuel pressure reg-
ulator. Refer to the Fuel Pump Module removal in
this section.
WARNING: FUEL SYSTEM PRESSURE MUST BE
RELEASED BEFORE SERVICING ANY FUEL SYS-
TEM COMPONENT. PERFORM THE FUEL SYSTEM
PRESSURE RELEASE PROCEDURE.
REMOVAL
(1) Spread tangs on pressure regulator retainer
(Fig. 15).
(2) Pry fuel pressure regulator out of housing.
(3) Ensure both upper and lower O-rings were
removed with regulator.
INSTALLATION
(1) Lightly lubricate the O-rings with clean engine oil
and place them into opening in pump module (Fig. 16).
(2) Push regulator into opening in pump module.
(3) Fold tangs on regulator retainer over tabs on
housing.
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, care-
fully pry back the locking tabs on fuel pump reser-
voir and remove the strainer (Fig. 17).
(3) Remove strainer O-ring from the fuel pump
reservoir body.
(4) Remove any contaminants by washing the
inside of the fuel tank.
INSTALLATION
(1) Lubricate the strainer O-ring with clean motor
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.
Fig. 14 Fuel Filter
1 – REAR CROSSMEMBER
2 – FUEL FILTER
3 – FUEL FILL NECK
Fig. 15 Fuel Pressure Regulator
1 – PRY BETWEEN REGULATOR AND HOUSING
2 – FUEL PRESSURE REGULATOR
3 – TABS (4)
Fig. 16 Fuel Pressure Regulator O-rings
1 – UPPER O-RING
2 – LOWER 0-RING
JX
FUEL SYSTEM
14 - 13
REMOVAL AND INSTALLATION (Continued)
(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 retaining tab and remove the fuel
pump/level sensor connector from the BOTTOM of
the fuel pump module electrical connector (Fig. 18).
NOTE: The pump module harness on TOP of flange
is not serviceable or removable.
(2) Using Special Tool C-4334 terminal remover or
equivlant, remove terminals from level sensor con-
nector (Fig. 19).
(3) Insert a screwdriver between the fuel pump mod-
ule and the top of the level sensor housing (Fig. 20).
Push level sensor down slightly.
(4) Slide level sensor wires through opening fuel
pump module (Fig. 21).
(5) Slide level sensor out of channel in module.
INSTALLATION
(1) Insert level sensor wires into bottom of opening
in module.
(2) Wrap wires into groove in back of level sensor
(Fig. 22).
Fig. 17 Inlet Strainer Removal
1 – TABS
2 – INLET STRAINER
Fig. 18 Fuel Pump/Level Sensor Electrical
Connector
1 – ELECTRICAL CONNECTOR
2 – RETAINING TABS
Fig. 19 Terminal Removal Tool
1 – TERMINAL REMOVAL TOOL
2 – FUEL LEVEL SENSOR CONNECTOR
Fig. 20 Loosening Level Sensor
1 – PRY AGAINST LEVEL SENSOR
2 – LEVEL SENSOR
14 - 14
FUEL SYSTEM
JX
REMOVAL AND INSTALLATION (Continued)
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