1996 CHRYSLER VOYAGER fuel cap release

(11) Using Special Tool 6856, remove plastic lock-
nut counterclockwise to release pump module (Fig.
16).
(12) Carefully remove pump module and O-ring
from tank (Fig. 17).
(13) Discard old O-ring.INSTALLATION
(1) Wipe seal area of tank clean and place a new
O-ring seal in position on pump.
(2) Position fuel pump in tank with locknut.
(3) Tighten locknut to 53 N´m (43 ft. lbs.).
(4) Connect fuel lines.
(5) Plug in electrical connector. Slide connector
lock into position.
(6) Raise fuel tank, install bolts into fuel tank
straps and tighten.
(7) Lower vehicle on hoist.
(8) Connect negative cable from battery.
(9) Fill fuel tank. Check for leaks.
(10) Install fuel filler cap.
FUEL PRESSURE REGULATOR
The fuel pressure regulator is part of the fuel
pump module (Fig. 18). Remove the fuel pump mod-
ule from the fuel tank to access the fuel pressure reg-
ulator.
WARNING: FUEL SYSTEM PRESSURE MUST BE
RELEASED BEFORE SERVICING ANY FUEL SYS-
TEM COMPONENT. PERFORM THE FUEL SYSTEM
PRESSURE RELEASE PROCEDURE.
REMOVAL
(1) Spread tangs on pressure regulator retainer
(Fig. 18).
(2) Pry fuel pressure regulator out of housing.
(3) Ensure both upper and lower O-rings were
removed with regulator.
INSTALLATION
(1) Lightly lubricate the O-rings with clean engine
oil and place them into opening in pump module (Fig.
19).
(2) Push regulator into opening in pump module.
Fig. 16 Fuel Pump Module Lock Nut Removal
Fig. 17 Fuel Pump Module Removal
Fig. 18 Fuel Pressure Regulator
14 - 14 FUEL SYSTEMNS
REMOVAL AND INSTALLATION (Continued)

(7) Install fuel pump module. Refer to Fuel Pump
Module in this section.
FUEL TANK
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove fuel filler cap and perform Fuel Sys-
tem Pressure Release procedure.
(3) Insert fuel siphon hose into fuel filler neck and
push it into the tank.
(4) Drain fuel tank dry into holding tank or a
properly labeledGASOLINEsafety container.
(5) Raise vehicle on hoist.
(6) Disconnect both the fuel fill and fuel vent rub-
ber hoses at the fuel tank.(7) Disconnect fuel supply lines from the steel sup-
ply line.
The fuel pump module electrical connector
has a retainer that locks it in place.
(8) Slide fuel pump module electrical connector
lock to unlock (Fig. 29).
(9) Push down on connector retainer (Fig. 30) and
pull connector off module.
(10) Use a transmission jack to support fuel tank.
Remove bolts from fuel tank straps.
(11) Lower tank slightly. Carefully remove filler
hose from tank.
(12) Lower the fuel tank. Disconnect pressure
relief/rollover valve hose at the front of tank. Remove
clamp and remove fuel filler tube vent hose. Remove
fuel tank from vehicle.
Fig. 28 Installation Channel
Fuel Tank
Fig. 29 Fuel Line Retainers and Pump Connector
Lock
Fig. 30 Pump Module Connector Retainer and Lock
NSFUEL SYSTEM 14 - 17
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Position fuel tank on transmission jack. Con-
nect pressure relief/rollover valve hose. Connect fuel
filler tube vent hose and replace clamp.
(2) Raise tank into position and carefully work
filler tube into tank. A light coating of clean engine
oil on the tube end may be used to aid assembly.
(3) Feed filler vent line thru frame rail. Careful
not to cross lines.
(4) Tighten strap bolts to 54 N´m (40 ft. lbs.)
torque. Remove transmission jack.
(5) Tighten filler hose clamp to 3.3 N´m (30 in.
lbs.).
CAUTION: Ensure straps are not twisted or bent
before or after tightening strap nuts.
(6) Connect fuel pump/module electrical connector.
Place retainer in locked position.
(7) Lubricate the fuel supply line with clean 30
weight engine oil, install the quick connect fuel fit-
ting. Refer to Tube/Fitting Assembly in the Fuel
Delivery section of this Group.
(8) Attach filler line to filler tube. Pull on connec-
tor to make sure of connection.
(9) Fill fuel tank, replace cap, and connect battery
negative cable.
CAUTION: When using the ASD Fuel System Test,
the ASD relay and 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.
(10) Use the DRB scan tool ASD Fuel System Test
to pressurize the fuel system. Check for leaks.
FUEL INJECTOR RAILÐ2.4L
REMOVAL
(1) Perform fuel system pressure release procedure
before servicing or starting repairs.Refer to
Fuel System Pressure Release Procedure in this sec-
tion.
(2) Disconnect negative cable from battery.
(3) Remove air cleaner inlet hose from throttle
body.
(4) Remove throttle cable and speed control cable
(if equipped) from throttle lever.
(5) Remove throttle cables from bracket by com-
pressing retaining tabs.
(6) Remove connector from throttle position sensor.
(7) Remove connector from idle air control motor.
(8) Remove vacuum lines from intake plenum fit-
tings (Fig. 31) and (Fig. 32).(9) Remove connector from intake air temperature
sensor (Fig. 32).
(10) Remove connector from MAP sensor (Fig. 33).
(11) Remove fuel hose quick connect fitting from
the chassis tube (Fig. 34).Refer to Fuel Hoses,
Clamps and Quick Connect Fittings in this Sec-
tion.Place a shop towel under the connections to
absorb any fuel spilled from the fitting.
Fig. 31 Vacuum Fitting on Rear of Intake Manifold
Fig. 32 Electrical and Vacuum Connections
14 - 18 FUEL SYSTEMNS
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Before installing an injector the rubber O-ring
must be lubricated with a drop of clean engine oil to
aid in installation.
(2) Install injector clip by sliding open end into the
top slot of the injector. The edge of the receiver cup
will slide into the side slots of clip.
(3) Install injector top end into fuel rail receiver
cap. Be careful not to damage O-ring during installa-
tion (Fig. 55).
(4) Repeat steps for remaining injectors.
(5) Connect fuel injector wiring.
FUEL INJECTORSÐ3.0L
WARNING: THE 3.0L MPI FUEL SYSTEM IS UNDER
A CONSTANT PRESSURE OF APPROXIMATELY 330
KPA (48 PSI). PERFORM FUEL PRESSURE
RELEASE PROCEDURE BEFORE SERVICING THE
FUEL INJECTORS.
REMOVAL
(1) Perform the Fuel Pressure Release Procedure.
(2) Disconnect negative cable from battery.
(3) The fuel rail must be removed first to service
the injectors. Refer to Fuel Injector Rail Assembly
Removal in this section.
(4) Label each injector connector with its cylinder
number. Disconnect electrical connector from injector.
(5) Position fuel rail assembly so that the fuel
injectors are easily accessible.
(6) Remove injector clip from fuel rail and injector
(Fig. 54).
(7) Pull injector straight out of fuel rail receiver
cup (Fig. 55).
(8) Check injector O-ring for damage. If O-ring is
damaged, it must be replaced. If injector is to be
reused, a protective cap must be installed on the
injector tip to prevent damage.
(9) Repeat procedure for remaining injectors.
INSTALLATION
(1) Before installing an injector, the rubber O-ring
must be lubricated with a drop of clean engine oil to
aid in installation.
(2) Being careful not to damage O-ring, install
injector nozzle end into fuel rail receiver cap.
(3) Install injector clip by sliding open end into
top slotof the injector. The edge of the receiver cup
will slide into the side slots of clip (Fig. 55)
(4) Repeat steps for remaining injectors.
(5) Install fuel rail assembly. Refer to Fuel Rail
Assembly Installation in this section.
(6) Connect electrical connectors to injectors in cor-
rect order.
(7) Connect negative battery cable.
CAUTION: When using the ASD Fuel System Test,
the ASD relay and 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.
(8) With the ignition key in ON position, access
the DRB scan tool ASD Fuel System Test to pressur-
ize the fuel system. Check for leaks.
Fig. 54 Fuel Injector and RailÐTypical
Fig. 55 Servicing Fuel InjectorÐTypical
NSFUEL SYSTEM 14 - 25
REMOVAL AND INSTALLATION (Continued)

fuel fitting. Refer to Tube/Fitting Assembly in the
Fuel Delivery section of this Group.
(7) Attach filler line to filler tube. Pull on connec-
tor to make sure of connection.
(8) Fill fuel tank, replace cap, and connect battery
negative cable.
FUEL RESERVOIR MODULE
REMOVAL
WARNING: THE FUEL RESERVOIR OF THE FUEL
MODULE DOES NOT EMPTY OUT WHEN THE TANK
IS DRAINED. THE FUEL IN THE RESERVOIR WILL
SPILL OUT WHEN THE MODULE IS REMOVED.
(1) Disconnect negative cable from battery.
(2) Insert fuel siphon hose into fuel filler neck and
push it into the tank.
(3) Drain fuel tank dry into holding tank or a
properly labeleddieselsafety container.
(4) Raise vehicle on hoist.
(5) Use a transmission jack to support the fuel
tank. Remove bolts from fuel tank straps. Lower
tank slightly.
(6) Clean area around fuel reservoir module and
tank to keep dirt and foreign material out of tank.
(7) Disconnect fuel lines from fuel module by
depressing quick connect retainers with thumb and
fore finger (Fig. 54).
(8) Slide module electrical connector lock to
unlock.
(9) Push down on connector retainer (Fig. 55) and
pull connector off module.
(10) Using Special Tool 6856, remove plastic lock-
nut counterclockwise to release pump module (Fig.
56).
(11) Carefully remove module and O-ring from
tank (Fig. 57).(12) Discard old O-ring.
INSTALLATION
(1) Wipe seal area of tank clean and place a new
O-ring seal in position on pump.
(2) Position fuel reservoir module in tank with
locknut.
(3) Tighten locknut to 58 N´m (43 ft. lbs.).
(4) Connect fuel lines.
(5) Plug in electrical connector. Slide connector
lock into position.
(6) Raise fuel tank, install bolts into fuel tank
straps and tighten.
(7) Lower vehicle on hoist.
(8) Connect negative cable from battery.
(9) Fill fuel tank. Check for leaks.
(10) Install fuel filler cap.
Fig. 54 Fuel Line Retainers and Pump Connector
Lock
Fig. 55 Module Connector Retainer and Lock
Fig. 56 Fuel Reservoir Module Lock Nut Removal
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 25
REMOVAL AND INSTALLATION (Continued)

FUEL DELIVERY SYSTEMÐ2.0L ENGINE
INDEX
page page
DESCRIPTION AND OPERATION
ELECTRIC FUEL PUMP.................. 28
FUEL DELIVERY SYSTEM................ 28
FUEL INJECTORS...................... 28
FUEL LEVEL SENSOR................... 28
FUEL PRESSURE REGULATOR........... 28
FUEL PUMP MODULE................... 28
FUEL TANK........................... 28
PRESSURE-VACUUM FILLER CAPÐ
2.0L ENGINE......................... 28
QUICK-CONNNECT FITTINGSÐ
2.0L ENGINE......................... 28
DIAGNOSIS AND TESTING
FUEL INJECTORSÐ2.0L ENGINE.......... 29
FUEL LEVEL SENSORÐ2.0L ENGINE....... 28
FUEL PUMP PRESSURE TESTÐ
2.0L ENGINE......................... 28SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE
PROCEDUREÐ2.0L ENGINE............ 29
HOSES AND CLAMPSÐ2.0L ENGINE....... 29
QUICK-CONNNECT FITTINGSÐ2.0L ENGINE . 29
REMOVAL AND INSTALLATION
ACCELERATOR PEDAL.................. 31
FUEL FILTERÐ2.0L ENGINE.............. 29
FUEL INJECTORS...................... 30
FUEL LEVEL SENSORÐ2.0L ENGINE....... 30
FUEL PRESSURE REGULATORÐ
2.0L ENGINE......................... 29
FUEL PRESSURE REGULATORÐ
2.0L ENGINE......................... 29
FUEL PUMP MODULEÐ2.0L ENGINE....... 29
FUEL TANKÐ2.0L ENGINE............... 30
TORQUE SPECIFICATION................ 31
DESCRIPTION AND OPERATION
FUEL DELIVERY SYSTEM
Refer to the Fuel Delivery Sytem in the Fuel Deliv-
ery Section of group 14 for the 2.4/3.0/3.3/3.8L
engines for more information.
FUEL PUMP MODULE
Refer to the Fuel Pump Module for the 2.4/3.0/3.3/
3.8L engines in the Fuel Delivery System section of
group 14.
ELECTRIC FUEL PUMP
Refer to the Electric Fuel Pump for the 2.4/3.0/3.3/
3.8L engines in the Fuel Delivery System Section of
group 14 for more information.
FUEL LEVEL SENSOR
Refer to the Fuel Level Sensor for the 2.4/3.0/3.3/
3.8L engines in the Fuel Delivery System section of
group 14 for more information.
FUEL PRESSURE REGULATOR
Refer to the Fuel Pressure Regulator for the 2.4/
3.0/3.3/3.8L engines in the Fuel Delivery System sec-
tion of group 14 for more information.
FUEL INJECTORS
Refer to the Fuel Injectors for the 2.4/3.0/3.3/3.8L
engines in the Fuel Delivery System section of group
14 for more information.
FUEL TANK
Refer to the Fuel Tank for the 2.4/3.0/3.3/3.8L
engines in the Fuel Delivery System section of group
14 for more information.
PRESSURE-VACUUM FILLER CAPÐ2.0L ENGINE
Refer to the Pressure-Vacuum Filler Cap for the
2.4/3.0/3.3/3.8L engines in the Fuel Delivery System
section of group 14 for more information.
QUICK-CONNNECT FITTINGSÐ2.0L ENGINE
Refer to the Quick Connect Fittings for the 2.4/3.0/
3.3/3.8L engines in the Fuel Delivery System section
of group 14 for more information.
DIAGNOSIS AND TESTING
FUEL PUMP PRESSURE TESTÐ2.0L ENGINE
Refer to the Fuel Pressure Test for the 2.4/3.0/3.3/
3.8L engines in the Fuel Delivery System section of
group 14 for more information.
FUEL LEVEL SENSORÐ2.0L ENGINE
Refer to the Fuel Level Sensor for the 2.4/3.0/3.3/
3.8L engines in the Fuel Delivery System section of
group 14 for more information.
14 - 28 FUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINENS/GS