Fuel System - Engine Sag/Poor Performance
85chrysler07Models
1981, 1982 and
1983 Through 1985 Aries/Reliant/Dodge 400/600/LeBaron/ E-Class/Caravelle/ New Yorker Front Wheel Drive Vehicles Equipped With 2.6L Engine
Subject
Sag and/or Poor Performance Due to Fuel Foaming
Index
DRIVEABILITY
Date
March 25, 1985
No.
18-06-85
This bulletin has been updated by bulletin # 18-06-86, dated 02/03/86, to include model years 1981 and 1982.
This bulletin supersedes Technical Service Bulletin # 14-48-84 for subject vehicles equipped with 2.6L engine.
SYMPTOM/CONDITION
Engine sags and/or exhibits poor performance following a hot soak restart. This condition occurs when cool incoming fuel meets the hot fuel in the carburetor fuel bowl which creates an over rich condition. Engine will start (unloading technique may be necessary).
DIAGNOSIS
Engine must be fully warmed up (fuel foaming does not affect cold engine driveability). The following are characteristics of fuel foaming:
^ Occurs primarily after hot soak restart or prolonged idle only on medium to heavy acceleration.
^ Sag is due to rich fuel mixture.
^ Black smoke at tailpipe.
^ Fuel pressure is normal.
^ Raw fuel at carburetor air horn.
^ Good accelerator pump discharge.
^ Will immediately start (unloading technique may be necessary).
PARTS REQUIRED
Pressure Regulator & Fuel Reservoir Package PN 4342937
Contains:
1 - Pressure Regulator Assembly PN 4307234
1 - Pressure Regulator Bracket PN 4306973
3 - Screw - Self-Tapping Bracket to Body PN 6031991
2 - Screw - Self-Tapping Pressure Regulator to Bracket PN 6033066
1 - Fuel Reservoir Assembly PN 4307358
8 - Hose Clamp - 1/4" PN 6500650
1 - Y-Connector Hose Assembly PN 4307397
1 - Hose Assembly - Reservoir to Pressure Regulator (18.5") PN 4307762
1 - Hose Assembly - Pressure Regulator to Carburetor (24") PN 4307763
1 - Clip - Hose-to-Valve Cover - Four Position PN 4307242
1 - Template - Pressure Regulator Bracket PN 4275240
1 - Fuel Flow Sensor Inlet Nipple (30~) PN 4307236
1 - Convolute Tube - 6" Long (fuel filter-to-fuel pump hose) PN 4279993
Must be ordered separately:
1- Authorized Modification Label PN 4275086
REPAIR PROCEDURE
1. Remove and discard the 90~ formed hose located between the fuel pump outlet and the carburetor inlet (hose between the fuel pump outlet and fuel flow sensor inlet, if equipped with fuel flow sensor).
If the vehicle has a fuel reservoir, disconnect the reservoir inlet hose at the pump and the outlet hose at the carburetor (outlet hose at fuel flow sensor inlet, if equipped with fuel flow sensor). Remove and discard the reservoir and hoses.
2. Remove the vapor return hose between the fuel pump and chassis return line. Install the Y connector/hose assembly, PN 4307397, with the curved leg of the Y connector pointing straight up. Connect the three hoses to the fuel pump vent, reservoir vent, and chassis fuel return line using 3 hose clamps, PN 6500650, as shown in Figure 1. Torque to 10 inch pounds.
3. Remove the thermostat housing bolt closest to the carburetor (already removed in Step 1 if car had a reservoir) and coat threads with Loctite/Mopar Sealant, PN 4318034. Install the reservoir assembly, PN 4307358, to the thermostat housing using the bolt just removed. Retorque the bolt to 12 to 17 foot pounds (Figure 1A).
4. Remove the existing hose clip on the valve cover and discard.
5. Attach the 7" long hose on the reservoir inlet to the fuel pump outlet nipple and clamp with hose clamp, PN 6500650 (Figure 1). Torque to 10 inch pounds.
FIGURE 2 - SPEED SENSOR RELOCATION:
6. Vehicles equipped with a speed sensor on the right shock tower or right fender shield may have to have it relocated to allow room for pressure regulator.
To relocate sensor, mark and drill 1/8" hole for upper sensor mount on right fender shield as shown in Figure 2. Re-attach sensor with upper screw. Adjust the speed sensor to a 30~ angle as shown, center punch, and drill 1/8" hole for the second attaching screw. Install the second screw and tighten both screws securely.
FIGURE 3 - DRILLING TEMPLATE PRESSURE REGULATOR BRACKET:
7. To mount the pressure regulator, tape the pressure regulator bracket template, PN 4275240, to the right side shock tower as shown in Figure 3. Carefully locate the template against the right fender shield and wheel well (keep the top side of the template level). Center punch three screw hole locations and drill three .165" diameter (#21 drill) holes. Attach the pressure regulator bracket with three selftapping screws, PN 6031991, tightening securely.
NOTE: SOME VEHICLES HAVE HEADLAMP-TO-DASH MAIN WIRING HARNESS ROUTING ATTACHED WITH A CLIP AT THE RIGHT SHOCK TOWER. IF SO, THE HARNESS MAY NEED TO BE REROUTED TO ALLOW ROOM FOR PRESSURE REGULATOR.
REMOVE WIRING FROM EXISTING CLIP AT RIGHT SHOCK TOWER AND DISCARD CLIP. DISCONNECT BOWL VENT HOSE CLIP LOCATED ON WHEEL WELL BELOW, AND ROUTE HARNESS THROUGH BOWL VENT HOSE CLIP. REATTACH BOWL VENT HOSE CLIP.
8. Attach the pressure regulator assembly, PN 4307234, to the bracket (Figure 1) using two self-tapping screws, PN 6033066. Tighten screws securely.
9. Rotate the clamp on the coolant hose near the fuel reservoir so no sharp metal corners contact the fuel hoses routed over the clamp.
Connect hose, PN 4307762, from the fuel reservoir outlet on the bottom of the reservoir to the pressure regulator inlet (lower fitting) (Figure 1). Route this hose over the coolant hose and under the ignition wires. Clamp with hose clamp, PN 6500650. Torque to 10 inch pounds.
10. Vehicles Equipped Without Fuel Flow Sensor
Connect hose, PN 4307763, from the pressure regulator outlet (upper fitting) to the carburetor fuel inlet (Figure 1). Clamp with hose clamp, PN 6500650. Torque to 10 inch pounds.
FIGURE 4:
Vehicles Equipped With Fuel Flow Sensor
Remove inlet nipple of fuel flow sensor and discard. Install new 30~ inlet nipple, PN 4307236, with nipple pointing to driver's side of car and slightly downward (Figure 4).
Remove the fuel filter-to-fuel pump hose at fuel filter and slide convolute sleeve, PN 4279993, over the fuel hose. Reattach the hose to the fuel filter using the original hose clamp.
Connect hose assembly, PN 4307763, from the pressure regulator outlet (upper fitting) to the fuel flow sensor inlet nipple routing the hose as shown in Figure 4. When installing hose clamp, PN 6500650, at the flow sensor, locate the clamp screw and tangs on the lower side of the hose so no sharp metal edges contact the fuel filter-to-fuel pump hose. Torque to 10 inch pounds.
11. Place the four fuel hoses listed below in clip, PN 4307242, starting with the hose closest to the attaching screw (Figure 1).
a. Chassis fuel supply line to fuel filter inlet hose.
b. Vapor return hose from the fuel pump and reservoir to the chassis return line.
c. Pressure regulator outlet to carburetor inlet hose (regulator-to-fuel flow sensor, if so equipped).
d. Fuel reservoir to pressure regulator inlet hose.
Close the top part of the clip over the hoses, attach clip with original hose clip screw, and tighten securely.
FIGURE 5:
12. Type Authorized Modification Label, PN 4275086, as shown in Figure 5 and attach near VECI label.
13. Check the pressure regulator, fuel reservoir, and hose clip for secure mounting. Check all fuel hoses for proper routing, making sure they are not contacting any sharp metal edges. Insure clamps are tight and make sure no sharp edges or clamp screws are contacting adjacent hoses or wires.
14. Start the engine and check the entire system for fuel leaks.
POLICY: Reimbursable within the provisions of the warranty
TIME ALLOWANCE:
Labor Operation No. 14-70-11-98 ...... ........ .. ...... .... 0.9 Hrs.
FAILURE CODE: AM - Authorized Modification