Fuel Tank - Rough Idle/Hesitation/Sags After Fillup
NO: 18-28-95GROUP: Vehicle Performance
DATE: Sep. 8, 1995
SUBJECT:
Rough Idle, Hesitation, Or Sags After Fuel Tank Is Filled
MODELS:
1996 (NS) Town & Country/Caravan/Voyager
NOTE:
This bulletin applies to vehicles built prior to Aug. 11, 1995 (MDH 0811XX).
SYMPTOM/CONDITION:
Engine idles rough, sags on acceleration, or hesitates, occurring shortly after the fuel tank is completely filled.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the 1996 2.4L/3.0L/3.3L/3.8L Caravan, Voyager, and Town & Country Powertrain Diagnostic Procedure Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin.
From the DRB III Select System menu select 1 Engine, then from the Select Function menu select 6 Monitor Display, then from the Monitors menu select 4 Adaptive Memory. Check the adaptive memory cells. If they are -25% or leaner, perform the Repair Procedure.
PARTS REQUIRED:
1 4874119 Tank, Fuel
1 4695227 0-ring, Fuel Pump Module
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NOTE:
To order parts, completely fill out a S.T.A.R. Center Contact Sheet (copy included) and fax it to 800-825-1980.
REPAIR PROCEDURE:
This bulletin involves installing a revised fuel tank.
1. Record the radio station presets and disconnect the negative battery cable.
2. 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).
3. Drain the fuel tank into an approved gasoline holding tank.
4. Raise the vehicle on an appropriate hoist.
5. Remove the three screws attaching the filler tube blocker and separate the blocker from the vehicle.
6. Disconnect the rollover valve harness to steel vent tube connection at the front of the tank.
7. Disconnect the fuel filter supply line from the steel fuel supply line.
8. Loosen the clamp on the filler tube hose at the tank connection.
9. 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.
10. Use a transmission jack to support the fuel tank. Remove the attaching bolts from the fuel tank retaining straps.
11. Lower the tank slightly. Carefully remove the filler tube hose from the fuel tank.
12. Disconnect the filler vents from the filler tube by squeezing the retainer and pulling the connector off of the steel tube.
13. Lower the fuel tank slowly while feeding the vent lines through the frame rail to remove the fuel tank from the vehicle.
14. Remove the fuel filter attaching screw, disconnect both fuel filter connectors from the fuel pump module and set the fuel filter aside for reuse later,
15. Remove the fuel pump module from the fuel tank and discard the 0-ring seal.
16. Install the fuel pump module into the new fuel tank (P/N 4874119) 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.
17. Tighten the fuel pump module lock nut to 40-45 ft. lbs. (54-61 Nm).
18. Attach the fuel filter 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.
19. Attach the fuel filter to the fuel tank and torque the screw to 35-45 in. lbs. (4-5 Nm).
20. Place the 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.
21. Line up the fuel filler tube hose with the fuel tank inlet neck and push it on.
22. 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).
23. 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.
24. Torque the fuel filler tube hose clamp at the fuel tank to 25-35 in. lbs. (3-4 Nm).
25. 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.
26. Attach the rollover valve harness hose to the steel vent tube at the front of the fuel tank.
27. Attach the fuel pump module electrical connector.
28. Install the fuel filler tube blocker and torque the fasteners to 45-55 in lbs. (5-6 Nm).
29. Lower the vehicle and fill the fuel tank.
30. Connect the negative battery cable.
31. Program the radio station presets and set the clock.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 14-60-01-93 0.9 Hrs.
FAILURE CODE: P8 - New Part