TSB P: Fuel Pump/Filter - Sag On Long Left Hand Turns

Details

86chrysler5 Models 1984-1987 Caravan, Voyager & Mini Ram Van With Vapor Lock Kit Installed Subject Sag on Long Left Hand Turns Index DRIVEABILITY Date December 15, 1986 No. 18-37-86 P-4440 This bulletin applies only to those vehicles with vapor lock packages from Technical Service Bulletin numbers 18-13-85 REV A, 18-18-85 REV A, 18-07-86, or 18-08-86 installed. SYMPTOM/CONDITION Vehicle may experience a sag when making a long sweeping turn, such as long curved freeway "on" ramps, or long curved uphill highways. This condition occurs at low fuel levels (1/4 tank or less) and is due to the in-tank filter being momentarily exposed to air. PARTS REQUIRED Rework Kit PN 4075490 Contains the following: 1 Fuel Hose PN 4419428 1 Fuel Filter PN 4419432 1 Fuel Hose Clamp PN 4419429 1 Fuel Hose Clamp PN 4419430 1 Plastic Strap PN 4419431 NOTE: THE IN-TANK GAUGE/PUMP UNIT ASSEMBLIES CONTAINED IN THE FOLLOWING LISTED PACKAGES HAVE BEEN UPDATED TO INCORPORATE THESE CHANGES IN THE FUEL PICK-UP TUBE ASSEMBLY. THIS HAS RESULTED IN PART NUMBER CHANGES TO THESE PACKAGES AND COMPONENT PARTS AS INDICATED. Applications/ Current Gauge/ New Gauge/ Current New TSB Affected Pump Unit Pump Unit Package Package 1984-86 2.2L/ 4075448 (15 gal) 4075479 4397604 4419418 18-13-85 REV A 4075449 (20 gal) 4075480 4397605 4419419 & 18-07-86 1984-86 2.6L/ 4075448 (15 gal) 4075479 4397606 4419420 18-18-85 REV A 4075449 (20 gal) 4075480 4397607 4419421 & 18-08-86 15 gallon service kit for service gauge only 4386734 4419433 20 gallon service kit for service gauge unit only 4397835 4419434 Fuel pump service kit for service pump unit only 4397833 4419435 Attached are revised pages for the vapor lock bulletins with part number changes as a result of the modification to the fuel pick-up tube and filter. Also included is a revised page where a note has been added pertaining to high altitude vehicles. These bulletin numbers and revised pages are as follows: Bulletin Number Pages to be Replaced 18-13-85 REVISION A Pages 2, 4, 7, and 8 18-18-85 REVISION A Pages 1, 4, and 7 18-07-86 Pages 2, 4, 7, and 8 18-08-86 Pages 1, 4, 5, and 7 Insert the revised pages in the appropriate bulletins. REPAIR PROCEDURES The following procedures involve the replacement of the 90~ formed hose (connecting the electric fuel pump to the gauge unit fuel tube) with a straight hose, and replacing the straight filter with a "T" filter. In addition to reworking vehicles with the vapor lock kits installed, any vapor lock kits or service kits for gauges and fuel pumps must also be reworked if they carry the old part numbers. This procedure applies to converting vapor lock packages to the updated packages. This same procedure also applies to reworking service gauge/pump units to the updated service packages. Rework kit, PN 4075490, must be used. 1. Locate gauge/pump unit, PN 4075448 or 4075449. If removal from gas tank is necessary, follow service manual procedure. FOR THE ENTIRE REWORK PROCEDURE USE EXTREME CAUTION NOT TO BEND THE FLOAT ARM AND HINGE ASSEMBLY. FIGURE 1: 2. Disconnect both black and red wire terminal attachments at the fuel pump and carefully bend back from fuel hose area. 3. Remove and discard both fuel hose clamps. Remove and discard the fuel hose containing the 90~ bend. Be sure to note the position of the fuel pump (Figure 1). FIGURE 2: 4. Remove and discard fuel pump inlet filters using caution so as not to damage pump inlet. 5. Install new fuel pump filter on fuel pump inlet (Figure 2). 6. Install new straight fuel hose on fuel pump plastic outlet tube, making sure hose has contact with tube shoulder. Install and crimp (Miller Tool C-4124 or equivalent) new fuel hose clamp (the larger of the two in the kit). 7. Slide new fuel hose clamp on fuel hose and install fuel hose (with pump attached) to gauge unit fuel tube. Be sure the pump and filter are correctly oriented (Figure 2). Align fuel hose clamp and crimp (Miller Tool C-4124 or equivalent). 8. Reconnect both black and red wires to fuel pump. Position plastic strap over red wire and attach (Figure 2). This procedure applies to converting service kits for service gauge units to the updated service packages. Rework kit, PN 4075490, must be used. 1. Remove and discard fuel hose clamp and fuel hose containing the 90~ bend from the gauge unit fuel tube. 2. Slide new fuel hose clamp (the smaller of the two in the kit) on new straight fuel hose, and install fuel hose to gauge unit fuel tube. Align fuel hose clamp and crimp (Miller Tool C-4124 or equivalent). 3. The remainder of the parts supplied in the kit will not be used. This procedure applies to converting service kits for service pump units to the updated service packages. Rework kit, FM 4075490, must be used. 1. Remove and discard fuel hose clamp and fuel hose containing the 90~ bend from the fuel pump plastic outlet tube. 2. Remove and discard fuel pump inlet filter, using caution so as not to damage pump inlet. FIGURE 2: 3. Install new fuel pump filter on fuel pump inlet fitting (Figure 2). 4. Install new straight fuel hose on fuel pump plastic outlet tube, making sure hose has contact with the tube shoulder. Install and crimp (Miller Tool C- 4124 or equivalent) new fuel hose clamp (the larger of the two in the kit). 5. The remainder of the parts supplied with the kit will not be used. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 14-50-01-92 . . . . . . . . . .0.8 Hrs. FAILURE CODE: RO - Driveability FUEL SENDING UNIT FRONT WHEEL DRIVE LABOR OPERATION TIME SCHEDULE