Chrysler Cirrus, Dodge Stratus, Plymouth Breeze Haynes. Manual - part 18

4-2

Chapter 4 Fuel and exhaust systems

2.3 The fuel pump module electrical connector is located in the

trunk, under the mat near the base of the left shock tower

3.4 On four-cylinder engines, connect a fuel pressure gauge to

the fuel rail at the test port

2

Fuel pressure relief procedure

Refer to illustration 2.3
Warning: Gasoline is extremely flammable,
so take extra precautions when you work on
any part of the fuel system. Don't smoke or
allow open flames or bare light bulbs near the

work area, and don't work in a garage where

a natural gas-type appliance (such as a water
heater or a clothes dryer) with a pilot light is
present. Since gasoline is carcinogenic, wear
latex gloves when there's a possibility of
being exposed to fuel, and if you spill any on
your skin, rinse it off immediately with soap
and water. Mop up any spills immediately and
do not store fuel-soaked rags where they
could ignite. The fuel system is under con-
stant pressure, so, if any fuel lines are to be
disconnected, the pressure must be relieved
first. When you perform any kind of work on
the fuel system, wear safety glasses and have
a Class B type fire extinguisher on hand.
1

Remove the fuel filler cap to relieve the

fuel tank pressure.
2

Working inside the trunk, fold back the

trunk mat near the base of the left shock
tower.
3

Locate the fuel pump electrical connec-

tor and disconnect it from the wiring harness
(see illustration).
4

Next, start the engine and allow it to run

until it stops. This should only take a few sec-
onds. Crank the engine again, to ensure the

fuel pressure is completely relieved. Before
working on any part of the fuel system, dis-
connect the negative battery cable from the
ground stud on the left shock tower (see

Chapter 5, Section 1).

5

Even after the fuel pressure has been

relieved, always lay a shop towel over any

fuel connection that is to be separated to
absorb the residual fuel that will leak out.
6

When you are finished working on the

fuel system, reconnect fuel pump electrical
connector to the wiring harness. Turn the
ignition key to the ON position a few times to
pressurize the system and check the serviced

area for leaks.
7

Install the fuel filler cap and tighten it

securely. Note: If the fuel filler cap seal allows
the fuel tank pressure to escape because of a
damaged seal or it has not been tightened
sufficiently, the CHECK ENGINE light will illu-
minate on the instrument panel.

3

Fuel pump/fuel pressure
regulator - check

Warning: Gasoline is extremely flammable,
so take extra precautions when you work on
any part of the fuel system (see the Warning
in Section 2).

Note 1: These vehicles are equipped with a
"returnless" fuel system in which the fuel

pressure regulator is part of the fuel pump
module and located inside the fuel tank.

Note 2: The fuel pump will operate as long as

the engine is cranking or running and the
PCM is receiving ignition reference pulses
from the electronic ignition system. If there
are no reference pulses, the fuel pump will
shut off after approximately 1 second.
Note 3: To perform the fuel pressure check,

you will need to obtain a fuel pressure gauge

and adapter set (fuel line fittings). On V6
engines, the fuel supply line is not equipped
with a fuel pressure test port (Schrader valve
fitting). A special fuel pressure test adapter
(factory tool No. 6539 or equivalent) must be
installed between the fuel supply line and the
fuel rail.

Preliminary check

Note: On all models, the fuel pump is located

inside the fuel tank (see Section 7).

1

If you suspect insufficient fuel delivery,

first inspect all fuel lines to ensure that the

problem is not simply a leak in a line.
2

Set the parking brake and remove the

fuel filler cap. Have an assistant turn the igni-
tion switch to the ON position while you listen
at the fuel filler neck opening. You should

hear a "whirring" sound, lasting for a couple

of seconds. Start the engine. The whirring

sound should now be continuous (although
harder to hear with the engine running). If
there is no sound, either the fuel pump fuses,
fuel pump, fuel pump relay, automatic shut-
down (ASD) relay or related circuits are
defective (proceed to Step 15).

System pressure check

Refer to illustrations 3.4 and 3.5
3

Perform the fuel pressure relief proce-

dure (see Section 2).
4

On four-cylinder engines, remove the

cap from the fuel pressure test port (Schrader
valve fitting) on the fuel rail and attach a fuel
pressure gauge (see illustration).
5

On V6 engines, the fuel supply line is not

equipped with a fuel pressure test port
(Schrader valve fitting). A special fuel pres-
sure test adapter (factory tool No. 6539 or
equivalent) must be installed between the fuel
supply line and the fuel rail. Disconnect the

fuel supply line from the fuel rail (see Sec-
tion 4) and install the fuel pressure test

adapter between the supply line and the fuel
rail (see illustration). Attach a fuel pressure

gauge to the test adapter fitting.
6

Start the engine and observe the pres-

sure reading on the gauge. Compare it with
the pressure listed in this Chapter's Specifi-
cations.
7

If the fuel pressure is higher than speci-

fied, check for a kinked or restricted fuel line
between the fuel filter and fuel pump module.

If the line is OK, replace the fuel pressure reg-

ulator (see Section 14).
8

If the fuel pressure is lower than speci-

fied, replace the fuel filter (see Section 15)
and perform the pressure check again. If it's
still low, remove the fuel pump module (see
Section 7) and inspect the fuel inlet strainer
for obstructions. If it's clogged, replace the
strainer. If the strainer is OK, replace the fuel
pump.
9

If there is no fuel pressure, check the

fuel pump, ASD and fuel pump relays as out-
li ned below.
10

Next, verify that the system holds pres-

sure. Note the fuel pressure with the engine

Chapter 4 Fuel and exhaust systems

4-3

3.5 On V6 engines, a special fuel pressure test adapter must be

installed between the fuel supply line and the fuel rail

125015-4-3.17

HAYNES

3.17 Fuel pump module electrical connector (body harness side)

Fuel pump (positive feed)
Fuel level sending unit (signal)
Fuel pump (ground)
Fuel level sending unit (ground)

1

2
3
4

running, then turn off the engine and observe

the reading on the fuel pressure gauge. The
fuel pressure should remain constant for a

minimum of one minute. A drop of more than
5 psi in one minute indicates an unaccept-
able leak in the system. If the pressure drop
is unacceptable, first visually inspect the sys-

tem for obvious leaks, especially at the quick
connect fittings.

11

If there aren't any obvious leaks, the fuel

is escaping either from one or more of the

fuel injectors or the fuel pressure regulator.

12

On four-cylinder engines, to perform the

following check it is necessary to install the
special fuel pressure test adapter (factory
tool No. 6539 or equivalent) between the fuel
rail and the fuel supply line. Perform the fuel
relief procedure (see Section 2) and install the
adapter and gauge set-up.

13

To determine where the fuel system is

leaking, pressurize the fuel system. With the
engine OFF, isolate the fuel injectors by
pinching off the rubber hose on the special
fuel pressure test adapter (factory tool No.
6539 or equivalent) between the fuel pressure
gauge and the fuel supply line. Observe the

reading on the fuel pressure gauge. If the fuel
pressure bleeds down there is a leak at one
or more of the injectors. Refer to Section 16
for further testing and replacement proce-
dures.
14 If the pressure remains constant, the

fuel injectors are OK and the fuel pressure

regulator must be replaced (see Section 14).

After the pressure tests are complete, per-
form the fuel pressure relief procedure (see

Section 2), remove the fuel pressure gauge

and adapter (if used) and assemble the
quick-connect fittings (see Section 4).

Component checks

Note: The fuel pressure regulator check is part

of the system pressure check (see above).

Fuel pump

Refer to illustration 3.17

15 If you cannot hear the fuel pump oper-

ate when energized (refer to preliminary
check above), use a test light or voltmeter to
verify the pump is receiving battery voltage.
16

Working inside the trunk, fold back the

trunk mat near the base of the left shock

tower. Locate the fuel pump 4-pin electrical
connector and disconnect it (see illustra-
tion 2.3).
17

Connect a test light or voltmeter to the

fuel pump positive feed and ground terminals
of the electrical connector (see illustration).
18

Have an assistant crank the engine -

battery voltage should be present at the elec-
trical connector. If voltage is present, replace
the fuel pump. If voltage is not present, check
the ASD and fuel pump relays (see below).

ASD and fuel pump relays

Refer to illustrations 3.20a, 3.20b, 3.21a,

3.21b, 3.23, 3.24 and 3.25

Note: The Automatic Shutdown (ASD) relay

and the fuel pump relay must both be tested

to insure proper fuel pump operation. Testing

procedures for the ASD relay and the fuel
pump relay are identical.

19

To access the relay box where the ASD

relay is located, remove air cleaner assembly
(see Section 9).

20

To test a relay, first remove it from its

location in the engine compartment Power
Distribution Center (PDC) (see illustrations).

4

3.20a The Automatic Shutdown relay (arrow) is located in the

Power Distribution Center under the square cover

3.20b The fuel pump relay (arrow) is located in the Power

Distribution Center under the rectangular cover

4-4

Chapter 4 Fuel and exhaust systems

TERMINAL LEGEND

NUMBER

I DENTIFICATION

30

COMMON FEED

85

COIL GROUND

86

COIL BATTERY

87

NORMALLY OPEN

87A

NORMALLY CLOSED

TERMINAL LEGEND

NUMBER

IDENTIFICATION

30

COMMON FEED

85

COIL GROUND

86

COIL BATTERY

87

NORMALLY OPEN

87A

NORMALLY CLOSED

3.21a ASD and fuel pump relay terminal identification

(rectangle type)

3.21b ASD and fuel pump relay terminal identification

(square type)

21

Verify that there is battery voltage at the

terminal in the PDC that corresponds with
terminal 30 of the relay (see illustrations).
This terminal should have voltage present at
all times. Now check the terminal in the PDC
that corresponds with terminal 86 on the

relay - it should have voltage present only

with the ignition key in the ON position.
22 If there is no voltage, check the fuel

pump fuses in cavities 8 and 10 in the PDC. If

voltage is not present at the fuse, check the
wiring and connectors to the PDC for a short,

broken wire or a bad connection.

23

Next, check relay operation by connect-

ing the probes of an ohmmeter to terminals
86 and 85 and measure the resistance. There
should be approximately 75 ohms resistance
(see illustration).
24

Now connect the ohmmeter probes to

terminals 30 and 87A and check for continu-

ity. Continuity should be present (see illus-

tration).

25

Check for continuity between terminals

30 and 87 (see illustration). There should be
no continuity.
26

Next, with the ohmmeter still connected

to relay terminals 87 and 30, use jumper

wires to connect the relay to the battery.
Connect the battery positive terminal to relay

terminal 86 and the battery negative terminal
to relay terminal 85. Continuity should exist

between terminals 87 and 30 when terminals
86 and 85 are energized. If continuity is not
present, replace the relay.

4

Quick-connect fittings and fuel
li nes - disassembly, assembly
and replacement

Warning: Gasoline is extremely flammable,
so take extra precautions when you work on
any part of the fuel system (see the Warning
in Section 2).

General information

1

Always perform the fuel pressure relief

procedure (see Section 2) before servicing
fuel lines or fittings.
2

The fuel supply and vapor lines extend

from the fuel tank to the engine compartment.
The lines are constructed of steel, plastic and
rubber. They are secured to the underbody
with clips and brackets. These lines should be

inspected for leaks, kinks and dents anytime
the vehicle is raised for service.
3

If evidence of dirt is found in the fuel

system or fuel filter during service, the
affected line should be disconnected and
blown out. Check the fuel inlet strainer on the
fuel pump module for blockage or contami-
nation (see Section 14).

Quick-connect fittings

4

Chrysler uses three different types of

quick-connect fittings to join various fuel
li nes and components. The first type uses a
single-tab retainer, the second type a two-
tab retainer and the third type incorporates a
plastic retainer ring (usually black in color)
which connects/disconnects much like a
common compressed air hose fitting. Some
are equipped with safety latch clips. The fit-
tings are equipped with non-serviceable 0-
ring seals located in the female part of the fit-
ting. In the event the fitting or tubing
becomes damaged or develops a leak,
replace the entire fuel line/quick-connect fit-
ting as an assembly. Always use original
equipment parts, or parts that meet or
exceed the original equipment standards.

3.23 Measure the resistance between

terminals 86 and 85 - it should be

approximately 75 ohms

3.24 Measure the resistance between

terminals 30 and 87A - continuity

should be present

3.25 Check for continuity between

terminals 30 and 87 - there

should be no continuity

Chapter 4 Fuel and exhaust systems

4-5'

4.5a Cross-sectional view of a two-tab quick-connect

fuel line fitting

WINDOW

TAB (2)

4.5b When properly assembled, the tab ear and shoulder on

the male fitting should be visible in the window

Single and two-tab retainer fittings

Disassembly

Refer to illustrations 4.5a, 4.5b, 4.9a and 4.9b
5

These quick-connect fittings have one or

2 windows (depending on type) located in the
side(s) of the female fitting. When the male fit-
ting is inserted into the female, the tab(s) on
the male engage in the window(s) and lock the
fitting together (see illustrations).
6

Perform the fuel pressure relief proce-

dure (see Section 2).
7

Remove all fasteners, brackets or clips

securing the lines as applicable.
8

Clean the area around the fitting to

remove dirt and foreign debris.

9

Depress the retaining tab(s) on the

quick-connect fitting and pull it apart (see
illustrations). Note: The retaining tabs and
shoulder should remain on the metal fuel line
after separation.

Assembly

10

Clean the male part of the fitting and

li ghtly lubricate it with clean engine oil.
11

Position the retaining tab ears on the

tube so they align with the windows in the
female fitting and push them together. You
should hear the fitting snap into place as the
retaining tab ears lock into the windows.

12

Verify the fitting is properly fastened by

trying to pull the lines apart.

13

Secure the fuel line using any clips or

brackets as applicable.

14

Pressurize the system and check for

leaks.

Plastic retainer ring fittings

Disassembly

Refer to illustration 4.18

15

Perform the fuel pressure relief proce-

dure (see Section 2).

16

Remove all fasteners, brackets or clips

securing the lines as applicable.

17

Clean the area around the fitting to

remove dirt and foreign debris.

18

Grasp the male line and push it in

(towards the fitting). While applying pressure
on the male line, press the plastic retainer ring
into the female fitting and then pull the male
li ne from the female fitting (see illustration).
Note: The plastic retainer ring must be pushed

4.9b ... and separate the fitting - to

assemble it, lubricate the male end with a

small amount of clean engine oil, then push
the fitting together until it locks into place -
tug on it to ensure the connection is secure

into the female fitting squarely! If it gets

cocked, the fitting will be difficult to separate. If

necessary, use an open-end wrench applied to

the plastic retainer to assist in evenly pressing

it into the female fitting. The plastic retainer
ring should remain attached to the female fit-

ting after separation.

Assembly

19

Clean the male part of the fitting and

li ghtly lubricate it with clean engine oil.
20 Insert the male end into the female and
push them together (see illustration 4.18).

You should hear the retainer ring snap into

4.9a Depress the plastic tabs on

the male fitting .. .

I NSTALLATION

PLASTIC

RETAINER

4.18 Plastic retainer ring type quick-connect fitting removal and installation

4-6

Chapter 4 Fuel and exhaust

systems

5.6 Fuel tank drain plug (arrow)

FUEL PUMP

MODULE

5.9 Fuel pump module fuel line fittings

place as it locks the fitting together. Make
sure the retainer ring is fully extended after
assembly.
21

Verify the fitting is properly fastened by

trying to pull the lines apart.
22

Secure the fuel line using any clips or

brackets as applicable.
23

Pressurize the system and check for

leaks.

Fuel lines - replacement

Steel tubing

24 If replacement of a metal line is required,
disassemble the applicable quick-connect fit-

tings as described above and remove the line

from the vehicle. If the quick-connect fitting is
damaged or leaks, replace the affected sec-

tion of fuel line/quick-connect fittings as an

assembly.
25 If the quick-connect fittings are accept-
able, a new piece of steel tubing may be
spliced-in to replace a damaged section by

flaring the tubing ends and joining them with a

union. Use tubing that meets or exceeds orig-
inal equipment standards. Do not use copper

or aluminum tubing to replace steel tubing.
These materials cannot withstand normal
vehicle vibration. Do not use a rubber hose to

replace a damaged section of steel tubing!

26

When installing the replacement section

into the line, assemble the quick-connect fit-

tings first, then tighten the unions. Warning:
Metal lines must never be allowed to rub
against other components or each other. A
minimum of 1/4-inch clearance must be
maintained to prevent contact unless it is

properly secured.

27

After replacing the line or section, pres-

surize the system and check for leaks.

Plastic lines

28 If replacement of a plastic line is
required, disassemble the applicable quick-
connect fittings as described above and
remove the line from the vehicle. The plastic
li nes used on these vehicles are not service-
able. If replacement is required, the affected
section of fuel line/quick-connect fittings

must be replaced as an assembly.

29 Install the new line onto the vehicle and
assemble the quick-connect fittings as appli-
cable (see above). Secure the line to the vehi-
cle as required. Warning: Plastic lines must
never be allowed to rub against other compo-
nents or each other. A minimum of 1/4-inch
clearance must be maintained to prevent
contact unless it is properly secured. Do not
route plastic fuel lines within four inches of
any part of the exhaust system or within ten
inches of the catalytic converter.
30

After replacing the line, pressurize the

system and check for leaks.

Rubber hoses

Warning: Fuel-injected vehicles use specially
constructed hoses. Only use hoses marked
EFM/EFI. Replace with only original equip-
ment hoses, or hoses that meet or exceed
original equipment standards. Others may
have a lower fatigue threshold.
31

Perform the fuel pressure relief proce-

dure (see Section 2).
32

Loosen the clamps securing the hose

and remove it from the vehicle.
33 Installation is the reverse of removal.

Warning: Do not route rubber fuel hoses

within four inches of any part of the exhaust

system or within ten inches of the catalytic
converter. Rubber hoses must never be
allowed to rub against other components or
each other. A minimum of 1/4-inch clearance
must be maintained to prevent contact with
other components unless it is properly
secured.
34

After replacing the hose, pressurize the

system and check for leaks.

5

Fuel tank - removal and

installation

Warning: Gasoline is extremely flammable,
so take extra precautions when you work on
any part of the fuel system (see the Warning
in Section 2).

Removal

Refer to illustrations 5.6 and 5.9

1

Remove the fuel tank filler cap to relieve

fuel tank pressure.
2

Perform the fuel pressure relief proce-

dure (see Section 2).
3

Disconnect the negative battery cable

from the ground stud on the left shock tower
(see Chapter 5, Section 1).
4

Working inside the trunk, fold back the

trunk mat near the base of the left shock
tower. Locate the fuel pump wiring har-
ness 4-pin connector and disconnect it from
the wiring harness (see illustration 2.3). Fol-
low the fuel pump wiring to the grommet at
the base of the rear seat. Push the grommet
through the floorpan and feed the wiring
and 4-pin connector through the hole.
5

Raise the vehicle and support it securely

on jackstands.
6

Position an approved gasoline container

under the fuel tank drain plug. If necessary,
use a funnel to prevent spilling fuel. Warning:
The fuel tank capacity is 16 gallons. Unless
the fuel tank is almost empty, be prepared to
collect a significant amount of fuel. Do not
leave the fuel tank draining operation unat-
tended. Be prepared to replace the drain plug
in case the fuel tank capacity exceeds the
container capacity. Remove the drain plug
(see illustration) and allow the fuel to exit the
fuel tank.
7

After the fuel has finished draining,

replace the drain plug and tighten it to the

torque listed in this Chapter's Specifications.

Warning: There will be approximately 1 to 2

gallons of fuel remaining inside the tank.

8

Loosen the clamp and detach the filler

neck hose from the fuel tank. Warning: There

may be fuel inside the filler neck and hose,
protect yourself accordingly.

9

Disconnect the quick-connect fuel line

fittings (see Section 4 if necessary) from the
fuel pump module (see illustration).

10

At the rear of the fuel tank, detach the

vapor hose from the rollover valve.

11

Support the fuel tank with a floor jack.

Chapter 4 Fuel and exhaust systems

4-7

FUEL LEVEL

SENSOR

7.6a Fuel pump module - component identification

7.6b When removing the fuel pump module from the fuel tank,

slightly angle the module to avoid damaging the fuel

level sending unit float arm

Place a piece of wood between the jack head
and the fuel tank to protect the tank.
12

Remove the fuel tank strap bolts and

straps.
13

On 1998 models, slightly lower the fuel

tank and detach the EVAP canister purge
li ne. Remove the hoses from the EVAP canis-
ter (see Chapter 6 if necessary) and discon-
nect the electrical connector from the Leak
Detection Pump (LDP). Note: Before discon-

necting any lines or hoses, clearly label the
hose and fitting so they can be reinstalled in

their proper locations.
14

Slightly lower the fuel tank and then

slide it forward to allow the filler neck to clear

the rear suspension crossmember. Remove
the tank from the vehicle.

Installation

15 Installation is the reverse of removal.
However, before installing the fuel tank, tie a
length of string or wire to the fuel pump mod-
ule wiring harness and route it through the
hole in the trunk floorpan. Once the fuel tank

is securely in position, pull the string to
access the wiring harness.

16

Tighten the fuel tank strap bolts to the

torque listed in this Chapter's Specifications.

6

Fuel tank cleaning and repair -
general information

Warning: Gasoline is extremely flammable,
so take extra precautions when you work on

any part of the fuel system. (See the Warning

in Section 2).
1

The fuel tank on these vehicles is made

of plastic and is not repairable.
2

If the fuel tank is removed from the vehi-

cle, do not place it in an area where sparks or
open flames could ignite the fuel vapors
escaping from the tank. Be especially careful
inside a garage where a natural gas-type
appliance is located, because the pilot light

could cause an explosion.

7

Fuel pump module - removal and
installation

Warning 1: Gasoline is extremely flammable,
so take extra precautions when you work on
any part of the fuel system (see the Warning
in Section 2).
Warning 2: The fuel reservoir in the fuel

pump module does not empty when the fuel

tank is drained. This fuel will drain out when
the fuel pump module is removed from the
fuel tank - protect yourself accordingly.
Caution: Be sure to change the fuel pump
module 0-ring seal whenever the assembly is
removed for service.
Note: The fuel pump module consists of the
following components; fuel pump, fuel pres-

sure regulator, fuel inlet strainer and fuel level
sending unit.

Removal

Refer to illustrations 7.6a and 7.6b
1

Perform the fuel pressure relief proce-

dure (see Section 2).
2

Disconnect the negative cable from the

remote battery terminal.

3

Remove the fuel tank from the vehicle

(see Section 5).

4

Clean the top of the fuel tank around the

fuel pump module to remove any dirt or
debris.
5

Using a large pair of pliers, remove the

fuel pump module ring nut. Caution: Do not
apply too much pressure on the ring nut dur-
ing removal or damage may result.
6

Remove the fuel pump module from the

tank (see illustrations). Angle the assembly
slightly to avoid damaging the fuel level send-
ing unit float arm. Remove and discard the 0-
ring seal.
7

The electric fuel pump is not service-

able. In the event of failure, the complete
assembly must be replaced. The only ser-
viceable parts on the fuel pump module are
the fuel inlet strainer, fuel pressure regulator
and the fuel level sending unit.

8

For service procedures on the fuel pres-

sure regulator and inlet strainer refer to Sec-

tion 14.

9

For service procedures on the fuel level

sending unit refer to Section 8.

Installation

10

Clean sealing area on the fuel tank.

Obtain the new fuel pump module 0-ring
seal. Lightly lubricate the 0-ring seal with
clean engine oil and install it on the fuel tank
opening.

11

Carefully insert the fuel pump module

into the fuel tank. Align the tab on the fuel
pump module with the notch in the fuel tank.

12

While holding the fuel pump module in

place, install the ring nut, tightening it
securely. Caution: Over-tightening the ring
nut may result in a leak.
13

The remaining installation steps are the

reverse of removal.

8

Fuel level sending unit - check
and replacement

Warning: Gasoline is extremely flammable,
so take extra precautions when you work on
any part of the fuel system (see the Warning
in Section 2).
Note: The fuel pump module consists of the
following components; fuel pump, fuel pres-

sure regulator, fuel inlet strainer and fuel level
sending unit.

Check

Refer to illustrations 8.3, 8.9 and 8.10

In-vehicle

1

Begin this procedure with the fuel tank

completely full.
2

Working inside the trunk, fold back the

trunk mat near the base of the left shock
tower. Locate the fuel pump wiring harness
4-pin connector and disconnect it from the
wiring harness (see illustration 2.3).

4

4-8

Chapter 4 Fuel and exhaust systems

1

Fuel level sending unit (ground)

2

Fuel pump (ground)

3

Fuel level sending unit (signal)

4

Fuel pump (positive feed)

FUEL PUMP

FUEL PUMP

GROUND

VOLTAGE SUPPLY

LEVEL SENSOR

GROUND

8.3 Fuel pump module electrical connector (fuel pump side)

terminal identification

8.9 Measuring the resistance of the fuel level sending unit with

the float arm in the FULL position

8.10 Measuring the resistance of the fuel level sending unit with

the float arm in the EMPTY position

8.13 Disconnect the electrical connector from the base of the fuel

pump module flange

3

Connect the probes of an ohmmeter to

the fuel level sending unit terminals of the fuel
pump module electrical connector and mea-
sure the resistance (see illustration). Com-
pare the measured resistance to the value
li sted in this Chapter's Specifications. If the
resistance is less than specified, replace the
fuel level sending unit.
4

Next, drive the vehicle until the fuel tank

is nearly empty or drain the fuel tank via the
drain plug into a container approved to hold
gasoline (see Section 5).
5

With the fuel tank empty, check the

resistance again (see illustration 8.3). Com-
pare the measured resistance to the value
li sted in this Chapter's Specifications. If the
resistance is out of tolerance, replace the fuel
level sending unit.

Removed from vehicle

6

A more thorough check of the fuel level

sending unit can be performed with the send-

ing unit removed from the vehicle.

7

Remove the fuel pump module (see

Section 7).
8

Connect the probes of an ohmmeter to

the fuel level sending unit terminals of the fuel

pump module electrical connector (see illus-

tration 8.3).

9

First, check the resistance of the send-

ing unit with the float arm in the FULL posi-

tion (see illustration). Compare the mea-

sured resistance to the value listed in this
Chapter's Specifications. If the resistance is
less than specified, replace the fuel level

sending unit.

10

Next, while observing the ohmmeter,

slowly lower the float arm to the EMPTY posi-
tion. The ohmmeter should register a smooth
change in resistance value from the FULL to

EMPTY position (see illustration). Compare

the measured resistance to the value listed in
this Chapter's Specifications. If the resis-
tance is out of tolerance or the ohmmeter
exhibited fluctuation during the transition
from FULL to EMPTY, replace the fuel level
sending unit.

Replacement

Refer to illustrations 8.13, 8.14, 8.15 and 8.17
11

Perform the fuel pressure relief proce-

dure (see Section 2).
12

Remove the fuel pump module (see

Section 7).

13

Disconnect the fuel level sensor/fuel

pump electrical connector from the base of

the fuel pump module flange (see illustra-
tion).

14

Use needle-nose pliers to remove the

blue locking wedge (see illustration).
15

Use a small screwdriver or needle-nose

pliers to lift the connector locking finger away
from the fuel level sending unit wire terminals
and then withdraw them from the module

8.14 Use needle-nose pliers and carefully

remove the blue locking wedge

Chapter 4 Fuel and exhaust systems

4-9

8.15 Use a small screwdriver, or needle-

nose pliers, and lift the locking fingers

away from the terminals, then carefully

remove the terminals from the connector

8.20 Terminal guide

for the fuel pump/fuel

level sending unit

(where it connects to

the base of the fuel

pump module flange)

electrical connector (see illustration).

16 If necessary, use factory tool No.

C-4334 or equivalent to remove the fuel level
sending unit terminals from the module con-
nector.

17

To remove the sending unit, insert a

screwdriver between the module fuel reservoir
and the top of the level sensor as shown and
pry the sensor down slightly (see illustration).

18

While guiding the sensor wires through

8.17 Using a screwdriver, pry the sensor

down slightly to disengage the

locking feature

the module fuel reservoir opening, slide the
sensor out of the channel.

Installation

Refer to illustrations 8.19 and 8.20

19

Place the wires into the guide groove on

the back side of the sending unit, route them
through the module fuel reservoir and then
slide the sensor up the channel until it snaps

into place (see illustration).

8.19 Place the wires into the groove on

the backside of the sending unit, then

while guiding the wires, slide the sending

unit up the channel until it snaps into

place - tug on it to ensure it's

locked into place

20 Install the wire terminals into the module

connector in their proper locations (see illus-

tration).
21

Install the blue locking wedge into the

module connector.
22

Verify the wire terminals are properly

installed in the module connector by gently
pulling on the wires.

23

Connect the fuel level sensor/fuel pump

electrical connector to the base of the fuel
pump module flange.
24

The remaining installation steps are the

reverse of removal.

9

Air cleaner assembly - removal

and installation

Removal

Refer

to illustrations 9.1a, 9.1b, 9.2, 9.4a and

9.4b

1

On the 2.0L four-cylinder engine and the

V6 engine, remove the air inlet resonator-to-

manifold bolts (see illustrations).

LEVEL SENSOR

GROUND

FUEL PUMP SUPPLY

LEVEL SENSOR

SIGNAL

4

MOUNTING BOLTS

9.1a Air inlet resonator-to-manifold bolts

(2.0L four-cylinder engine only)

9.1b Removing the air inlet resonator bolt (V6 engine)