1996 CHRYSLER VOYAGER fuel

hydrocarbons. Vapors from the fuel tank are collected
in a charcoal filled canister. The vapors are held in
the canister until the engine is operating. When the
engine is running, the vapors are drawn through the
intake manifold into the combustion chambers.
PRESSURE-VACUUM FILLER CAP
The loss of any fuel or vapor out of the filler neck
is prevented by the use of a safety filler cap. The cap
will release pressure only under significant pressure
of 10.9 to 13.45 kPa (1.58 to 1.95 psi). The vacuum
release for all gas caps is between 0.97 and 2.0 kPa
(0.14 and 0.29 psi). The cap must be replaced by a
similar unit if replacement is necessary.
WARNING: REMOVE FILLER CAP TO RELIEVE
TANK PRESSURE BEFORE REMOVING OR REPAIR-
ING FUEL SYSTEM COMPONENTS.
QUICK-CONNECT FITTINGS
Different types of quick-connect fittings are used to
attach various fuel system components. These are: a
single-tab type, a two-tab type or a plastic retainer
ring type. Some are equipped with safety latch clips.
Refer to the Removal/Installation section for more
information.
CAUTION: The interior components (o-rings, spac-
ers) of quick-connect fitting are not serviced sepa-
rately. Do not attempt to repair damaged fittings or
fuel lines/tubes. If repair is necessary, replace the
complete fuel tube assembly.
Fuel tubes connect fuel system components with
plastic quick-connect fuel fittings. The fitting con-
tains non-serviceable O-ring seals (Fig. 4).
CAUTION: Quick-connect fittings are not serviced
separately. Do not attempt to repair damaged quick-
connect fittings or fuel tubes. Replace the complete
fuel tube/quick-connect fitting assembly.
The quick-connect fitting consists of the O-rings,
retainer and casing (Fig. 4). When the fuel tube
enters the fitting, the retainer locks the shoulder of
the nipple in place and the O-rings seal the tube.
DIAGNOSIS AND TESTING
FUEL PUMP PRESSURE TEST 2.4/3.3/3.8L
WARNING: FUEL SYSTEM PRESSURE MUST BE
RELEASED BEFORE A FUEL SYSTEM HOSE OR
COMPONENT IS DISCONNECTED.The fuel system operates at approximately 338 kPa
(49 psi), 3.3L uses approximately 379 kPa (55 psi).
Check fuel system pressure at the test port on the
fuel rail (Fig. 5) or (Fig. 6).
Fig. 4 Plastic Quick-Connect Fittings
Fig. 5 Fuel Pressure Test PortÐ2.4L
14 - 6 FUEL SYSTEMNS
DESCRIPTION AND OPERATION (Continued)

(1) Remove cap from fuel pressure test port on fuel
rail.
(2) Connect Fuel Pressure Gauge C-4799B to test
port (Fig. 7).
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.
(3) Place the ignition key in the ON position.
Using the DRB scan tool, access ASD Fuel System
Test. The ASD Fuel System Test will activate the fuel
pump and pressurize the system.²If the gauge reading equals 338 kPa (49 psi)
3.3L uses approximately 379 kPa (55 psi) further
testing is not required. If pressure is not correct,
record the pressure.
²If pressure is above specifications, check for a
kinked or restricted fuel return tube (from filter to
pump module). If the fuel return tube is not pinched
or restricted, replace the fuel pressure regulator.
²If fuel pressure is below specifications, refer to
the diagnosis chart for Fuel Pressure Below Specifi-
cations.
(4)Replace Pressure test port cap when fin-
ished doing pressure test.
Fig. 6 Fuel Pressure Test PortÐ3.3/3.8LFig. 7 Checking Fuel Pressure at Fuel Rail
NSFUEL SYSTEM 14 - 7
DIAGNOSIS AND TESTING (Continued)

FUEL PRESSURE BELOW SPECIFICATIONS
14 - 8 FUEL SYSTEMNS
DIAGNOSIS AND TESTING (Continued)

FUEL LEVEL SENSOR
This procedure tests the resistance of the level sen-
sor itself. It does not test the level sensor circuit.
Refer to Group 8W - Wiring Diagrams for circuit
identification.
The level sensor is a variable resistor. Its resis-
tance changes with the amount of fuel in the tank.
The float arm attached to the sensor moves as the
fuel level changes. To test the level sensor, connect
an ohmmeter across the sensor signal and sensor
ground terminals of the fuel pump module connector
(Fig. 8). Move the float lever to the positions shown
in the resistance chart (Fig. 8). Record the resistance
at each point. Replace the level sensor if the resis-
tance is not within specifications.
FUEL INJECTORS
For fuel injector diagnosis, refer to the Fuel Injec-
tor Diagnosis charts. For poor fuel economy diagnosis
or engine miss, also refer to Transmission Driveplate
in this section.
Fig. 8 Level Sensor Diagnosis
NSFUEL SYSTEM 14 - 9
DIAGNOSIS AND TESTING (Continued)

FUEL INJECTOR DIAGNOSIS
14 - 10 FUEL SYSTEMNS
DIAGNOSIS AND TESTING (Continued)

SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE
PROCEDUREÐ2.4/3.3/3.8L
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.
(1) Disconnect negative cable from battery.
(2) Remove fuel filler cap.
(3) Remove protective cap from fuel pressure test
port on fuel rail (Fig. 9) or (Fig. 10).
(4) Place open end of fuel pressure release hose,
tool number C-4799-1, into an approved gasoline con-
tainer. Connect other end of hose C-4799-1 to fuel
pressure test port (Fig. 11). Fuel pressure will bleed
off through the hose into the gasoline container. Fuel
gauge C-4799-B contains hose C-4799-1.
(5)Replace Pressure test port cap when fin-
ished doing pressure test.
FUEL SYSTEM PRESSURE RELEASE
PROCEDUREÐ3.0L ENGINE
(1) Remove the Fuel Pump relay from the Power
Distribution Center (PDC). For location of the relay,
refer to the label on the underside of the PDC cover.
(2) Start and run engine it stalls.
(3) Attemp restarting engine until it will no longer
run.(4) Turn ignition key to OFF position.
CAUTION: Steps 1, 2, 3 and 4 must be performed to
relieve high pressure fuel from within the fuel rail.
Do not attempt to use the following steps to relieve
this pressure as excessive fuel will be forced into a
cylinder chamber.
(5) Unplug connector from any injector.
(6) Attach one end of a jumper wire with alligator
clips (18 gauge or smaller) to either injector terminal.
(7) Connect the other end of the jumper wire to
the positive side of the battery.
(8) Connect one end of a second jumper wire to the
remaining injector terminal.
CAUTION: Supplying power to an injector for more
than 4 seconds will permantely damage the injector.
Do not leave the injector connected to power for
more than 4 seconds.
Fig. 9 Fuel Pressure Test PortÐ2.4L
Fig. 10 Fuel Pressure Test PortÐ3.3/3.8L
Fig. 11 Releasing Fuel Pressure
NSFUEL SYSTEM 14 - 11

(9) Momentarily touch the other end of this
jumper wire to the negative terminal of the battery
for no more than 4 seconds.
(10) Place a rag or towel below the fuel line at the
quick connect to the rail.
(11) Disconnect the quick connect fitting to the
rail. Refer to Quick-Connect Fittings in this section.
(12) Return the fuel pump relay to the PDC.
(13) One or more Diagnostic Trouble Codes (DTC's)
may have been stored in the PCM memory due to the
fuel pump relay removal. The DRB scan tool must be
used to erase a DTC. Refer to group 25, On-Board
Diagnostics.
HOSES AND CLAMPS
Inspect all hose connections (clamps and quick con-
nect fittings) for completeness and leaks. Replace
cracked, scuffed, or swelled hoses. Replace hoses that
rub against other vehicle components or show sign of
wear.
Fuel injected vehicles use specially constructed
hoses. When replacing hoses, only use hoses marked
EFM/EFI.
When installing hoses, ensure that they are routed
away from contact with other vehicle components
that could rub against them and cause failure. Avoid
contact with clamps or other components that cause
abrasions or scuffing. Ensure that rubber hoses are
properly routed and avoid heat sources.
The hose clamps have rolled edges to prevent the
clamp from cutting into the hose. Only use clamps
that are original equipment or equivalent. Other
types of clamps may cut into the hoses and cause
high pressure fuel leaks. Tighten hose clamps to 1
N´m (10 in. lbs.) torque.
QUICK-CONNECT FITTINGS
REMOVAL
When disconnecting a quick-connect fitting, the
retainer will remain on the fuel tube nipple.
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE DISCONNECTING A QUICK-CONNECT FIT-
TINGS. REFER TO THE FUEL PRESSURE RELEASE
PROCEDURE.
(1) Disconnect negative cable from battery.
(2) Perform Fuel Pressure Release Procedure.
Refer to the Fuel Pressure Release Procedure in this
section.
(3) Squeeze retainer tabs together and pull fuel
tube/quick-connect fitting assembly off of fuel tube
nipple. The retainer will remain on fuel tube.
INSTALLATION
CAUTION: Never install a quick-connect fitting
without the retainer being either on the fuel tube or
already in the quick-connect fitting. In either case,
ensure the retainer locks securely into the quick-
connect fitting by firmly pulling on fuel tube and fit-
ting to ensure it is secured.
(1) Using a clean lint free cloth, clean the fuel tube
nipple and retainer.
(2) Prior to connecting the fitting to the fuel tube,
coat the fuel tube nipple with clean 30 weight engine
oil.
(3) Push the quick-connect fitting over the fuel
tube until theretainer seats and a click is heard.
(4) The plastic quick-connect fitting has windows
in the sides of the casing. When the fitting com-
pletely attaches to the fuel tube, the retainer locking
ears and the fuel tube shoulder are visible in the
windows. If they are not visible, the retainer was not
properly installed (Fig. 12).Do not rely upon the
audible click to confirm a secure connection.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay remains energized
for either 7 minutes, until the test is stopped, or
until the ignition switch is turned to the Off posi-
tion.
(5) Use the DRB scan tool ASD Fuel System Test
to pressurize the fuel system. Check for leaks.
REMOVAL AND INSTALLATION
FUEL FILTER
The fuel filter mounts to the top of the fuel tank.
The inlet and outlet tubes are permanently attached
to the filter (Fig. 13).
Fig. 12 Plastic Quick-Connect Fitting/Fuel Tube
Connection
14 - 12 FUEL SYSTEMNS
SERVICE PROCEDURES (Continued)

WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE DISCONNECTING QUICK-CONNECT FIT-
TINGS AT FUEL FILTER. REFER TO THE FUEL
PRESSURE RELEASE PROCEDURE.
REMOVAL
(1) Perform fuel system pressure release.
(2) Disconnect quick-connect fittings from fuel
pump module and chassis fuel supply tube. Refer to
Quick-Connect Fittings in this section.
(3) Remove filter retaining screw (Fig. 13) and
remove filter from tank.
INSTALLATION
(1) Install fuel filter to tank.
(2) The fuel supply (to filter) tube, return tube (to
pump module) and fuel supply (to chassis fuel line)
are permanently attached the fuel filter. The ends of
the fuel supply and return tubes have different size
quick-connect fittings.
(3) Apply a light coating of clean 30 weight engine
oil to the fuel filter nipples. Install fuel tubes. Refer
to Fuel Tubes and Quick-Connect Fittings in this sec-
tion.
FUEL PUMP MODULE
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.
WARNING: THE FUEL RESERVOIR OF THE FUEL
PUMP MODULE DOES NOT EMPTY OUT WHEN THE
TANK IS DRAINED. THE FUEL IN THE RESERVOIR
WILL SPILL OUT WHEN THE MODULE IS
REMOVED.
REMOVAL
(1) Remove fuel filler cap and perform Fuel Sys-
tem Pressure Release procedure.
(2) Disconnect negative cable from battery.
(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) Use a transmission jack to support the fuel
tank. Remove bolts from fuel tank straps. Lower
tank slightly.
(7) Clean area around fuel tank module and tank
to keep dirt and foreign material out of tank.
(8) Disconnect fuel lines from fuel pump module by
depressing quick connect retainers with thumb and
fore finger (Fig. 14).
(9) Slide fuel pump module electrical connector
lock to unlock.
(10) Push down on connector retainer (Fig. 15) and
pull connector off module.
Fig. 13 Fuel Filter
Fig. 14 Fuel Line Retainers and Pump Connector
Lock
Fig. 15 Pump Module Connector Retainer and Lock
NSFUEL SYSTEM 14 - 13
REMOVAL AND INSTALLATION (Continued)