Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 15
(3) Connect Fuel Pressure Gauge C-4799 to fuel rail
service valve. (Fig. 8)
CAUTION: When using the ASD Fuel System Test, the
ASD relay and fuel pump relay remain energized for 7
minutes or until the test is stopped, or until the
ignition switch is turned to the Off position.
(4) Place the ignition key in the ON position. Using
the DRB II tester, access ASD Fuel System Test. The
ASD Fuel System Test will activate the fuel pump and
pressurize the system.
If the gauge reading the specification listed in the
Fuel System Pressure chart, further testing is not
required. If pressure is not correct, record the pressure
and remove gauge. Use the DRB II ASD Fuel System
Test to pressurize the system. Ensure fuel does not
leak from the fuel rail service valve. Reinstall protec-
tive cover onto fuel rail service valve.
If pressure is below specifications, proceed to Fuel
System Pressure Below Specifications. If pressure is
above specifications, proceed to Fuel System Pressure
Above Specifications.
Fuel System Pressure Below Specifications
If the fuel pressure reading in step (4) was below
specifications, test the system according to the follow-
ing procedure.
WARNING: FUEL SYSTEM PRESSURE MUST BE RE-
LEASED BEFORE A FUEL SYSTEM HOSE OR COM-
PONENT IS DISCONNECTED.
(a) Perform Fuel Pressure Release procedure.
(b) Install Fuel Pressure Gauge C-4799 and Fuel
Pressure Adapter 6433 in the fuel supply line be-
tween the fuel tank and fuel filter (Fig. 6).
(c) Using the DRB II, with the ignition key in the
ON position, repeat the ASD Fuel System Test.
• If pressure is at least 5 psi higher than reading
recorded in step (4), replace fuel filter.
• If no change is observed, gently squeeze return
hose. If pressure increases, replace pressure regulator.
If the gauge reading does not change when the return
hose is squeezed, the problem is either a plugged inlet
strainer or defective fuel pump.
Fuel System Pressure Above Specifications
If the fuel pressure reading in step (4) was above
specifications test the system according to the follow-
ing procedure.
WARNING: FUEL SYSTEM PRESSURE MUST BE RE-
LEASED BEFORE A FUEL SYSTEM HOSE OR COM-
PONENT IS DISCONNECTED.
(a) Perform Fuel Pressure Release procedure.
(b) Install Fuel Pressure Gauge C-4799 and Fuel
Pressure Adapter 6433 in the fuel supply line (Fig. 6)
between the fuel tank and fuel filter.
(c) Remove the fuel return line hose from the fuel
pump at fuel tank. Connect Fuel Pressure Test
Adapter 6541 to the return line. Place the other end
of adapter 6541 into an approved gasoline container
(minimum 2 gallon size). All return fuel will flow into
container.
(d) Using the DRB II, with the ignition key in the
ON position, repeat the ASD Fuel System Test.
• If pressure is now correct, replace fuel pump
assembly.
• If pressure is still above specifications, remove
fuel return hose from chassis fuel tubes (at engine).
Attach Fuel Pressure Test Connect Adapter 6541 to the
fuel return hose and place other end of hose in clean
container (Fig. 7). Repeat test. If pressure is now
correct, check for restricted fuel return line. If no
change is observed, replace fuel pressure regulator.
Fig. 7 Fuel Return Connection
Fig. 8 Pressure Test Gauge
.
FUEL SYSTEM
14 - 7
FUEL PUMP/LEVEL SENDING UNIT ASSEMBLY
REMOVAL—FRONT WHEEL DRIVE
The fuel tank must be removed to service the fuel
pump/level sending unit assembly. Refer to Fuel Tank
Section for fuel tank removal.
(1) Using a hammer and a brass drift, carefully tap
the lock ring counterclockwise to release assembly
(Fig. 9).
(2) Remove fuel pump/level sender assembly and
O-ring seal from tank. Discard old seal.
(3) Prevent dirt from entering the tank by covering
the fuel tank openings.
FUEL PUMP INLET STRAINER
REMOVAL—FRONT WHEEL DRIVE
(1) Gently bend locking tabs on fuel pump reservoir
assembly to clear locking tangs on the fuel pump filter.
(Fig. 10)
(2) Remove strainer.
(3) Remove strainer O-ring from the fuel pump res-
ervoir body.
(4) If the inlet strainer is plugged or dirty, clean the
fuel tank.
FUEL PUMP INLET STRAINER
INSTALLATION—FRONT WHEEL DRIVE
(1) Lightly lubricate the strainer O-ring with Mopar
Silicone Spray Lube.
(2) Insert strainer O-ring into outlet of strainer. The
O-ring must sit evenly on the step inside the filter
outlet.
(3) Push strainer onto the inlet of the fuel pump
reservoir body. Ensure the locking tabs on the reservoir
body lock over the locking tangs on the filter.
FUEL LEVEL SENDING UNIT DIAGNOSIS
Refer to Group 8—Electrical
FUEL LEVEL SENDING UNIT
REMOVAL—FRONT WHEEL DRIVE
(1) Bend locking tab and remove electrical connector
from the bottom of the fuel pump electrical connector
(Fig. 11).
(2) Remove terminal locking cover (red). Remove
sending unit wiring terminals from the electrical con-
nector.
(3) Use a wide blade screwdriver to release the
sending unit locking tab (Fig. 12). Use another wide
blade screwdriver to push on the sending unit body.
(4) Slide the entire fuel level sending unit off of the
fuel pump/reservoir body.
(5) Carefully pull the wires through the coverplate
and reservoir body.
FUEL LEVEL SENDING UNIT
INSTALLATION—FRONT WHEEL DRIVE
(1) Carefully bend the level unit wires and lay into
the slot on the back of the level unit.
(2) Slide the level unit into the slots on the fuel
pump/reservoir assembly. Feed the wires through the
triangular hole in the fuel pump/reservoir body. Make
sure that the tab on the level unit locks into the detente
in the fuel pump/reservoir assembly.
Fig. 9 Fuel Pump Service—Front Wheel Drive
Fig. 10 Fuel Pump Inlet Strainer—Front Wheel Drive
Fig. 11 Fuel Pump Electrical Connector—Front
Wheel Drive
14 - 8
FUEL SYSTEM
.
(3) Slip wires into tab on the fuel pump/reservoir
assembly.
(4) Carefully install the level unit wiring terminals
into the electrical connector. Install terminal locking
cover.
(5) Install the electrical connector into the bottom of
the fuel pump electrical connector. Ensure that the
connector is fully locked into position.
FUEL PUMP/LEVEL UNIT ASSEMBLY
INSTALLATION—FRONT WHEEL DRIVE
(1) Wipe seal area of tank clean and place a new
O-ring seal in position on pump.
(2) Position fuel pump in tank with locking ring.
(3) Using a hammer and brass drift, tap ring around
clockwise to lock pump in place.
CAUTION: Over tightening the pump lock ring may
result in a leak.
(4) Install tank. Refer to the Fuel Tank Section in
this Group.
FUEL PUMP MODULE REMOVAL—ALL WHEEL
DRIVE
The fuel tank must be removed to service the fuel
pump/level sending unit assembly. Refer to Fuel Tank
Section of this Group for fuel tank removal.
(1) Unclip fuel vapor hose and fuel drain hose from
fuel tank (Fig. 13).
The fuel pump module is spring loaded. It will rise up
slightly when the band clamp is removed.
(2) While holding down on the fuel pump module,
remove the band clamp from top of module (Fig. 14).
(3) Remove the fuel pump module from fuel tank.
Discard flat rubber seal.
FUEL PUMP INLET STRAINER REMOVAL—ALL
WHEEL DRIVE
(1) Remove the fuel pump from the fuel tank. Refer
to Fuel Pump Module Removal in this section.
(2) Bend locking tabs on the strainer to clear locking
tangs on the fuel pump module (Fig. 15).
(3) Remove strainer.
(4) If the strainer is plugged or dirty, clean the fuel
tank.
FUEL PUMP INLET STRAINER
INSTALLATION—ALL WHEEL DRIVE
(1) Align the orientation tabs in the strainer with
the slot in the bottom of the fuel pump module.
(2) Push strainer onto the inlet of the fuel pump
module. Make sure that the locking tabs on the filter
snap over the tangs on the pump module.
(3) Install the fuel pump module into the fuel tank.
Refer to Fuel Pump Module Installation in this section.
FUEL LEVEL SENDING UNIT DIAGNOSIS
Refer to Group 8—Electrical
Fig. 12 Fuel Level Sending Unit—Front Wheel Drive
Fig. 13 Hose Tank Clips—All Wheel Drive
Fig. 14 Band Clamp Removal—All Wheel Drive
.
FUEL SYSTEM
14 - 9
FUEL LEVEL SENDING UNIT REMOVAL—ALL
WHEEL DRIVE
(1) Remove the fuel pump from the fuel tank. Refer
to Fuel Pump Module Removal in this section.
(2) Remove the two screws holding fuel level sending
unit in place. (Fig. 16)
(3) Disconnect electrical leads.
FUEL LEVEL SENDING UNIT
INSTALLATION—ALL WHEEL DRIVE
(1) Connect electrical leads to the fuel level sending
unit.
CAUTION: Do not press against the sending unit
during installation.
(2) Install level sending unit and tighten screws.
(3) Install the fuel pump module into the fuel tank.
Refer to Fuel Pump Module Installation in this section.
FUEL PUMP MODULE INSTALLATION—ALL
WHEEL DRIVE
(1) Wipe clean the seal area of tank. Place a new seal
in position on pump.
CAUTION: Fuel pump module must be properly
aligned during installation.
(2) Position fuel pump module so that the arrow on
the edge of the module is between the two lines molded
into the fuel tank (Fig. 17).
The fuel pump module is spring loaded. The module
must be held down when installing the band clamp.
(3) Compress fuel pump module. Install band clamp
and tighten to 5.0 N
Im (40 in. lbs.) torque.
(4) Install fuel tank. Refer to the Fuel Tank Section
in this Group.
FUEL FILTER—FRONT WHEEL DRIVE
REMOVAL
WARNING: FUEL SYSTEM PRESSURE MUST BE RE-
LEASED BEFORE THE FUEL FILTER IS REMOVED.
(1) Perform fuel system pressure release.
(2) Remove filter retaining screw and remove filter
assembly from rail (Fig. 18).
(3) Loosen outlet hose clamp on filter and inlet hose
clamp on rear fuel tube.
(4) Wrap a shop towel around hoses to absorb fuel.
Remove hoses at filter and fuel tube. Discard clamps.
Fig. 16 Fuel Level Sending Unit—All Wheel Drive
Fig. 15 Fuel Strainer Service—All Wheel Drive
Fig. 17 Fuel Pump Module Alignment—All Wheel
Drive
14 - 10
FUEL SYSTEM
.
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