Repair Procedure

This bulletin involves installing a spacer on the fuel level unit and IF the bottom of the fuel tank is bowed upward installing a revised fuel tank.

1. Perform the appropriate fuel system pressure release procedure described on page 14-9 of the 1996 Town & Country, Caravan And Voyager Service Manual (Publication No. 81-370-6105).

2. Drain the fuel tank into an approved gasoline holding tank.

3. Record the radio station presets, disconnect and isolate the negative battery cable.

4. Raise the vehicle on an appropriate hoist.

5. Use a transmission jack to support the fuel tank. Remove the attaching bolts from the fuel tank retaining straps. Lower the tank slightly.

6. Clean the area around the fuel pump module and tank to prevent foreign material from getting into the fuel tank.

7. Disconnect the fuel lines from the fuel pump module by depressing the quick connect retainers with thumb and fore finger.

8. Slide the fuel pump module electrical connector lock to the unlocked position. Push down on the connector retainer and pull the connector from the module.

9. Using Special Tool 6856, turn the plastic lock nut counterclockwise to release the fuel pump module.

10. Remove the fuel pump module from the fuel tank. Cut and discard the 0-ring seal.

11. Depress the retaining tab and remove the fuel pump/level sensor wiring connector from the electrical connector at the bottom of the fuel pump module mounting flange.

12. Insert a screwdriver between the fuel pump module and the top of the [1][2]fuel level sensor housing. Push the fuel level sensor down slightly.

13. Slide the [1][2]fuel level sensor out of the installation channel of the module.

14. Slide spacer P/N 4883322 into the installation channel so its "V"-shaped channel is on the wire side of the installation channel and the "V"-shaped channel of the spacer captures the [1][2]fuel level sensor wires. The spacer should slide all the way to the top end of the installation channel.

15. Make sure the [1][2]fuel level sensor wires are routed in the slot at the top of the back side of the fuel level sensor, then slide the fuel level sensor up into the installation channel until it "snaps" into place. Be sure the tab at the bottom of the sensor locks in place and the spacer is tight between the fuel pump module body and the fuel level sensor.

16. Connect the fuel pump/level sensor wiring connector to the fuel pump module.

NOTE:
IF THE BOTTOM OF THE FUEL TANK IS NOT BOWED UPWARD SKIP TO STEP 25.

17. Remove the three screws attaching the filler tube blocker and separate the blocker from the vehicle.

18. Disconnect the rollover valve harness to steel vent tube connection at the front of the tank.

19. Disconnect the fuel filter supply line from the steel fuel supply line.

20. Loosen the clamp on the filler tube hose at the tank connection.

21. Carefully remove the filler tube hose from the fuel tank.

22. Disconnect the filler vents from the filler tube by squeezing the retainer and pulling the connector off of the steel tube.

23. Lower the fuel tank slowly while feeding the vent lines through the frame rail to remove the fuel tank from the vehicle.

24. Remove the fuel filter attaching screw and transfer it and the fuel filter to the revised fuel tank (P/N 4883140). Torque the screw to 35-45 in. lbs. (4-5 Nm).

25. Insure the seal area of the fuel tank that is to be used is clean and install the fuel pump module into the tank using a new 0-ring seal (P/N 4695227). Make sure the locating tab on the fuel pump module is lined up with the notch on the fuel tank.

26. Torque the fuel pump module lock nut to 40-45 ft. lbs. (54-61 Nm) using Special Tool 6589.

27. Attach the fuel filter lines to the fuel pump module by pushing the fittings onto the tubes until the retainers seat. Pull back on the connectors to make sure they are secure.

NOTE:
IF THE FUEL TANK WAS NOT REPLACED SKIP, TO STEP 30.

28. Place the revised fuel tank on a transmission jack and slowly raise it into position while feeding the fuel filler vent lines through the frame rail. Make sure the vent lines are not crossed on top of the fuel tank.

29. Line up the fuel filler tube hose with the fuel tank inlet neck and push it on.

30. Raise the tank up to the underbody and install the fuel tank retention straps. Torque the fasteners to 30-50 ft. lbs. (40-68 Nm).

NOTE:
IF THE FUEL TANK WAS NOT REPLACED, SKIP TO STEP 36.

31. Attach the filler vent lines to the filler tubes by pushing the connectors on until they are seated. Pull back on the connectors to make sure they are secure.

32. Torque the fuel filler tube hose clamp at the fuel tank to 25-35 in. lbs. (3-4 Nm).

33. Push the fuel filter supply line connector onto the steel fuel supply line until it is seated. Pull back on the connectors to make sure they are secure.

34. Attach the rollover valve harness hose to the steel vent tube at the front of the fuel tank.

35. Install the fuel filler tube blocker and torque the fasteners to 45-55 in lbs. (5-6 Nm).

36. Attach the fuel pump module electrical connector.

37. Lower the vehicle and refuel it with fuel drained into an appropriate holding tank in step 2.

38. Connect the negative battery cable.

39. Program the radio station presets and set the clock.