Файл: 92FWD_14.pdf

GENERAL INFORMATION

The fuel tanks of Chrysler Corporation built vehicles are equipped with fuel and vapor controls that allow the vehicle to pass a full 360° rollover without fuel leakage.

The fuel delivery system used on front wheel drive vehicles contains a fuel tank pressure relief/rollover valve. The valve mounts on the top of the fuel tank. The valve functions as a pressure relief valve while the vehicle is upright. The valve also contains a check valve that prevents fuel from escaping from the fuel tank if the vehicle turns over.

The fuel filler cap also acts as a pressure/vacuum valve. When pressure inside the fuel tank gets too high or too low, the fuel filler cap opens to relieve the difference in air pressure.

An evaporation control system restricts fuel evaporation into the atmosphere and reduces unburned hydrocarbons. Vapors from the fuel tank are collected in a charcoal filled canister. The vapors are held in the canister until the engine is operating. When the engine operates, vapors are drawn through the intake manifold into the combustion chambers.

FUEL TANK FILLER TUBE

As a reminder, a label that reads Unleaded Fuel Only is attached to the instrument panel under the fuel gauge. A similar label is located near the fuel tank filler.

PRESSURE VACUUM FILLER CAPS

The loss of any fuel or vapor out of the filler neck is prevented by the use of a safety filler cap. The cap releases only under significant pressure 10.9 to 13.45 kPa (1.58 to 1.95 psi). The vacuum release for all gas caps is between .97 and 2.0 kPa (.14 and .29 psi). The cap must be replaced by a similar unit in order for the system to remain effective.

WARNING: REMOVE FILLER CAP TO RELIEVE TANK PRESSURE BEFORE REMOVING OR REPAIRING FUEL SYSTEM COMPONENTS.

FUEL TANK CAPACITIES

FUEL SYSTEM PRESSURE RELEASE PROCEDURE

The 2.2L/2.5L TBI engine fuel system is regulated to a constant pressure of approximately 270 kPa (39 psi). The fuel systems of 3.0L and 3.3L engines are regulated to a constant pressure of approximately 330 kPa (48 psi). The 2.2L Turbo III and 2.5L Turbo I fuel system pressure is regulated to approximately 55 psi.

Fuel system pressure must be released before servicing any fuel system component.

(1)Remove fuel filler cap to release fuel tank pres-

sure.

(2)Disconnect injector wiring harness from engine or main harness.

(3)Connect a jumper wire from terminal Number 1 (ground) of the injector harness (Fig. 1) to engine ground.

(4)Connect one end of a jumper wire to terminal Number 2 (positive) of the injector harness (Fig. 1). Connect the other end to the positive post of the battery for no longer than 5 seconds. This releases system pressure.

(5)Remove jumper wires.

(6)Continue fuel system service.

FUEL TANK

DRAINING FUEL TANK

(1)Remove fuel filler cap.

(2)Perform the Fuel System Pressure Release procedure.

(3)Remove ground cable from battery.

(4)Raise vehicle on hoist.

Fig. 1 Injector Harness Connectors

(5)Remove rubber cap from drain tube. The tube is located on rear of fuel tank. Connect either a portable holding tank or a siphon hose to the drain tube (Fig. 2).

(6)Drain fuel tank, until dry, into holding tank or a properly labeled Gasoline safety container.

Fig. 2 Drain Tube Connection Location

FUEL TANK REMOVAL

(1)Perform fuel system pressure release.

(2)Drain fuel tank. Refer to Draining Fuel Tank in this section.

(3)Remove fuel filler tube to quarter panel screws (Fig. 3).

(4)Raise vehicle on hoist. Some models will require removal of the right rear wheel to access the fuel filler tube.

WARNING: WRAP SHOP TOWELS AROUND HOSES TO CATCH ANY GASOLINE SPILLAGE.

(5)Disconnect fuel pump and gauge sending unit electrical connectors.

(6)Disconnect the fuel supply and return hoses from fuel pump. Refer to Quick Connect Hoses in the Fuel Delivery section of this group.

(7)Support tank with transmission jack. Loosen tank mounting straps and lower tank slightly. Remove hose from pressure relief/rollover valve.

(8)Carefully work fuel filler tube from tank.

(9)Remove tank mounting straps and lower tank.

INSTALLATION

(1)Position fuel tank on transmission jack. Connect vapor separator/rollover valve hose and position insulator pad on fuel tank. Position vapor vent so that it is not pinched between tank and floor pan during installation.

(2)Raise tank and fuel filler tube carefully into position. Use a light coating of power steering fluid to ease fuel filler tube installation. Ensure filler tube grommet is not damaged. Verify that the tube is installed correctly.

(3)Tighten fuel tank strap nuts to 23 NIm (250 in. lbs.) torque. Remove transmission jack. Ensure straps are not twisted or bent.

(4)Lubricate the metal tubes on the fuel pump with clean 30 weight engine oil. Install the quick connect fuel fittings. Refer to Tube/Fitting Assembly in the Fuel Delivery section of this Group.

(5)Lower the vehicle.

(6)Attach filler tube to filler neck opening in quarter panel. Tighten quarter panel screws to 2 NIm (17 in. lbs.) torque.

(7)Fill fuel tank, install filler cap, and connect battery cable.

CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) Relay remains energized for either 7 minutes, until the test is stopped, or until the ignition switch is turned to the Off position.

(8) Use the DRB II tester ASD Fuel System Test to pressurize the fuel system. Check for leaks.

FUEL PUMP

Refer to the Fuel Delivery section for fuel pump service.

FUEL RESERVOIR

The fuel reservoir is internal to the fuel pump assembly. The purpose is to provide fuel at the fuel pump intake during all driving conditions, especially when low fuel levels are present.