Chrysler Repair: 1991 chrysler 2.5L fuel pump not working, fuel pump relay, motor brushes


Question
QUESTION: Hi Roland:
Thanks for your help checking my fuel pump relay.It appears to be ok...  The engine will start if I hammer on the fuel tank with a hammer...any tips on changing out the in tank pump

ANSWER: Hi Jim,
You have to drain and remove the tank and then remove the pump module. It is about a total of 12 steps in and the same out. I can type all this in but it will take a while to do so. Or I can xerox copy and postal mail it to you if time permits. The site doesn't allow scanning in documents. My manual is a '93 so I can't be certain it is the same for your '91. Use the 'thank and rate' tab to let me know if you want me to type this up, and if so I'll do so tonight and be ready to paste it in to a follow-up question from you tomorrow. The other approach would be to tell me a postal mailing address and I'll xerox and mail it to you tomorrow from here in California. Let me know either way.
Roland

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QUESTION: Hi Roland:
Any idea why the pump works when I beat on the tank ?

Jim

ANSWER: Hi Jim,
Other than the motor ground wire (black) or the power wire (dark green/black) is flaky or the plug-in to the pump module is loose/corroded, the pump motor brushes must be wearing out or the armature of the motor similarly worn. You could check that by shaking the harness and the splice for the black ground wire to see if you can induce the affect that you are getting with the hammer. If the only way to get it to work is by tapping on the tank itself then that suggests the pump motor is failing.
I did type in the procedure for replacing the module as a follow-up to my ealier answer, so watch for that to show up in your in box toward the end of the day (1200 GMT). It is based on the manual I have for '93.
Roland

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QUESTION: Hi Roland:
I have seen where some recommend a new wire harness.  I was happy to find a new pump for $67 instead of $170.  I don't know if you sent the typed proceedure yet...I have not seen it.  I will be getting my pump thursday
thank you for your help    Jim


Answer
Hi Jim,
I typed in an "added to answer" from a 'reader' yesterday morning. I am writing to tech support to see if I can get them to deliver it to you. It should have been distributed at 1200 GMT, about 23 hours ago.
Let me know if it doesn't come by Thursday and I'll do it again.
Roland