Electric Fuel Pump - High Frequency Whine
91chrysler04
NO.: 14-02-91
GROUP: FUEL
DATE: May 6, 1991
SUBJECT: Noisy In-Tank Electric Fuel Pump
MODELS:
1989-90 (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V
VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
SYMPTOM/CONDITION:
Vehicle may exhibit a high frequency noise or whine, coming from the in-tank electric fuel pump. This noise is most noticeable inside the vehicle when the engine is at idle.
PARTS REQUIRED:
1 Fuel Pump Noise Package 4638270
Package Contents:
1 Ballast Resistor (.5 ohm) 4638266
1 Relay and Bracket Assembly 4638267
1 Vacuum Switch 4638268
1 Overlay Harness Assembly 4638269
1 Screw - Hex Head, Self-Tapping 9426638
2 Clamp - Vacuum Hose 6032174
1 Gasket - Bulkhead Connector 4331711
1 Insulator - 2 Terminal, Female 4274937
1 Insulator - 2 Terminal, Male 4209927
1 Insulator Wedge (blue) 4209935
1 Insulator Wedge (red) 4209934
1 Vacuum Tee J3239827
2 Clamp - Vacuum Hose 2448761
REPAIR PROCEDURE:
This procedure involves the installation of a wiring overlay harness and ballast resistor.
1. Verify that ignition key is in the OFF position and disconnect negative battery cable.
2. Remove the two bolts attaching the windshield washer reservoir to the dash panel. Remove the washer reservoir.
3. Loosen the bolt that holds the bulkhead connector together and disconnect the connector. Remove and discard the foam gasket from the terminal end of the connector. Remove the blue wedge from the fuel pump terminal # 24 in the bulkhead connector (see page 8W-154 in the 1989 Front Wheel Drive Van/Wagon Service Manual, and pages 8W-160, 161, and 162 in the 1990 Front Wheel Drive Van/wagon Service Manual).
4. Remove the tape that holds the rubber boot to the back of the connector and roll back the boot to expose the wires. Locate the dark green wire with the black tracer. From the terminal end of the connector, using a small screwdriver (pick), release the plastic locking finger that holds the terminal into the connector. While depressing the lock finger, pull the wire to remove it from the connector.
5. On the overlay harness assembly (supplied with the package), locate the two wires with bare terminals. Feed these two wires through the opening in the rubber boot at the back of the bulkhead connector.
6. Push the flat blade terminal on the pink wire with the black tracer into cavity # 24 of the bulkhead until it locks into place. Install the blue wedge previously removed from the connector.
7. Push the flat blade terminal on the dark green wire with the black tracer (previously removed from the bulkhead connector) into one of the cavities of the female two-way connector provided in the package. Install the blue wedge, provided in the package, to lock the terminal in place.
8. Push the terminal on the dark green wire with the black tracer (from the overlay harness) into the male two-way connector. Be sure that the cavity used corresponds to the cavity used in the female two-way connector. Install the red wedge, provided in the package, to lock the terminal in place.
9. Connect the female and male two-way connectors together, again making sure that the wires are in corresponding cavities. Tuck the connectors up into the rubber boot of the bulkhead connector. Position the connectors toward the top of the rubber boot to prevent interference when joining the bulkhead connector halves together.
10. Roll the rubber boot back down over the wires and seat it into the back of the bulkhead connector. Tape the boot to the connector with electrical tape. Install the new foam gasket provided in the package.
11. Connect the bulkhead connector and tighten the bolt that holds it together.
12. Install the windshield washer reservoir.
13. Route the overlay harness around the left shock tower to the auto shutdown relay.
Figure 1:
14. Remove the bolt that attaches the auto shutdown relay (Figure 1) to the main relay rail on the left inner fender.
15. Connect the square connector on the overlay harness to the fuel pump relay provided in the package. Attach the fuel pump relay and auto shutdown relay to the relay rail using the bolt removed in step 14.
16. Remove the bolt at the rearward end of the main relay rail that attaches it to the inner fender.
17. Connect the round connector on the overlay harness to the vacuum switch provided in the package. Connect the vacuum hose from the harness to the vacuum switch, using one of the clamps provided to secure it. Attach the vacuum switch and the main relay rail to the inner fender using the bolt removed in step 16. Make sure that the vacuum switch is mounted in a vertical direction with the electrical connection facing downward.
Figure 2:
18. On vehicles not equipped with speed control, remove the cap on the vacuum nipple on the brake booster. Attach the other end of the vacuum hose from the overlay harness to the brake booster nipple, using the other clamp provided to secure it. If the vehicle is equipped with speed control, disconnect the servo vacuum hose at the brake booster. Cut the hose approximately halfway between the small check valve and the end of the hose (see Figure 2). Insert the vacuum tee, provided in the package, into the servo vacuum hose where it has been cut. Attach the hose from the overlay harness to the small opening of the vacuum tee and use the clamp provided to secure it. Connect the servo hose on the brake booster fitting and secure with the clamp.
19. Locate the dimple in the left inner fender just above the starter relay. Drill or punch a 5/32" hole in the dimple.
Figure 1:
20. Attach the ballast resistor provided to the left inner fender using the hex head self-tapping screw provided. Drive the screw into the hole drilled in step 19 (Figure 1), and tighten to 2.8 N-m (25 in.lbs.) torque. Overtightening the screw can cause the resistor to crack or the hole to strip. Connect the two one-way connectors from the overlay harness to the ballast resistor.
21. Remove the lower nut on the windshield wiper motor bracket stud. Place the ground eyelet from the overlay harness over the stud. Replace the nut and tighten to 7.4 N-m (65 in.lbs.) torque.
22. Start vehicle and verify correct fuel system operation.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No. 14-50-01-96 . . . . . . . . . . . . . . . . 0.9 Hrs.
FAILURE CODE: 68 - Noisy