Repair Procedure

This bulletin involves replacing the fuel pump module and if necessary installing a fuel pump jumper harness.

1. Perform the fuel system pressure release procedure.

a. Disconnect the negative cable from the battery.

b. Remove the fuel filler cap.





c. Remove the protective cap from the fuel pressure test port on the fuel rail (refer to Figure 1).

d. Place the open end of fuel pressure release hose (Tool No. C-4799-1 contained in Fuel Gauge C-4799-A) into a properly labeled gasoline safety container. Connect the other end of hose C-4799-1 to the fuel pressure test port. Fuel pressure will bleed off through the hose into the gasoline container.

2. Remove the screws holding the fuel tank filler tube to the opening in the quarter panel.

3. Perform the fuel tank draining procedure.

a. Raise the vehicle on an appropriate hoist.





b. Remove the rubber cap from the fuel tank drain tube. The cap is located above the rear differential torque tube, on the inboard side of the fuel tank (refer to Figure 2). Connect a portable gasoline holding tank to the drain tube.

c. Completely drain the fuel tank into the holding tank.

4. Perform the fuel tank removal procedure.





a. Remove the fasteners holding the park brake cable support bracket assembly in place (refer to Figure 3).





b. Use a transmission jack to support the fuel tank. Remove the bolts from the fuel tank straps (refer to Figure 4).

c. Loosen the fuel filler tube vent hose clamp and remove the hose from the tube.

d. Lower the tank slightly.

e. Clean the quick connectors to remove ALL dirt (use air pressure or an appropriate cleaning agent).

WARNING:
WRAP SHOP TOWELS AROUND THE HOSES TO CATCH ANY GASOLINE SPILLAGE THAT MAY OCCUR WHEN THEY ARE DISCONNECTED FROM THE FUEL TUBES.

f. Disconnect the fuel supply and return hoses from the chassis fuel tubes by pushing in on the black plastic release ring (the side of an open end wrench may be used to aid in pushing on the release ring) and pulling on the connector.

g. Disconnect the vapor hose.

h. Cover the hose ends/fittings to prevent contamination.








j. Slide the locking retainer of the fuel pump module electrical connector to the unlocked position. Depress the retainer tab and pull the connector loose from the fuel pump module (refer to Figures 5 and 6).

k. Pull the fuel filler vent hose through the frame rail.

m. Lower the fuel tank.

NOTE:
THOROUGHLY WASH THE FUEL TANK IN THE AREA OF THE FUEL PUMP MODULE TO PREVENT ANY DIRT AND/OR FOREIGN MATERIAL FROM FALLING INTO THE FUEL TANK.

5. Perform the fuel pump module removal procedure.





a. Unclip the fuel vapor hose and the fuel drain hose from the fuel tank (refer to Figure 7).

b. While holding down on the fuel pump module, remove the band clamp from the top of the module. The fuel pump module is spring loaded and will rise up slightly when the band clamp is removed.

c. Remove the fuel pump module from the fuel tank and discard it and the flat rubber seal.

6. Perform the fuel pump module installation procedure.

a. Wipe clean the seal area of the fuel tank. Place the new seal that is packaged with the replacement fuel pump module in position on the pump.

CAUTION:
THE FUEL PUMP MODULE MUST BE PROPERLY ALIGNED DURING INSTALLATION.





b. Position the fuel pump module so the arrow on the edge of the module is between the two lines molded into the fuel tank (refer to Figure 8).

c. Press down on the top of the fuel pump module to compress it. Install the band clamp and torque to 40 in.lbs. (5 N-m).

7. Install fuel pump jumper harness (P/N 4688378) on 1991 - 1993 vehicles, if not previously installed. This harness will have already been installed if the fuel pump module has been replaced before and fuel pump module P/N 4761646 was used.

8. Perform the fuel tank installation procedure.

a. Position the fuel tank on a transmission jack.

b. Raise the fuel tank while inserting the fuel filler vent hose through the hole in the frame rail.

c. Ensure the black release rings of the supply and return fuel hose quick-connect fittings are in the OUT position. The release rings should be loose and free floating.

d. Lubricate the ends of the chassis fuel supply and return lines with clean 30 weight engine oil.

CAUTION:
WHEN MAKING CONNECTIONS WITH QUICK-CONNECT FITTINGS, ALWAYS PULL BACK ON THE FITTING TO CHECK FOR COMPLETE ENGAGEMENT. IF THE FITTING WILL NOT FULLY CONNECT, MAKE SURE THE BLACK RELEASE RING IS NOT JAMMED INTO THE METAL CASING OF THE FITTING. IF THE FITTING FAILS, REPLACE IT WITH A NEW ONE OF CORRECT SIZE.

e. Couple the quick-connect fittings of the fuel supply and return hoses to the chassis fuel tubes.

f. Connect the vapor hose and the drain tube (be sure the cap is installed on the end of the drain tube) to the fuel pump module.

g. Raise the fuel tank into position. Carefully twist the filler tube and fuel filler vent tube into position. Be sure to not kink the hose.

CAUTION:
BE SURE THE STRAPS ARE NOT TWISTED OR BENT BEFORE AND AFTER TIGHTENING THE STRAP FASTENERS.

h. Install the fuel, tank support straps. Torque the fasteners to 40 ft.lbs. (54 N-m). Remove the transmission jack.

j. Connect the fuel filler vent hose and tighten the hose clamp.

k. Install the park brake cable support bracket. Torque the fasteners to 200 in.lbs. (23 N-m).

m. Lower the vehicle.

n. On affected models, install the gasket between the filler tube and the inner quarter panel before installing the mounting screws. Attach the fuel filler tube to the opening in the quarter panel. Torque the screws to 17 in.lbs. (2 N-m).

o. Fill the fuel tank, install the fuel tank cap.

p. Connect the negative battery cable.

CAUTION:
WHEN USING THE ASD FUEL SYSTEM TEST, THE ASD RELAY AND THE 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.

q. Pressurize the fuel system using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III). With the ignition switch in the run position, use the ASD Fuel System Test, check for leaks.

POLICY:
Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:
Labor Operation No. 14-50-01-99 1.2 Hrs.

FAILURE CODE: 53 - Improper Pressure