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Chrysler Le Baron, Dodge Dynasty, Plymouth Acclaim. Manual - part 21

FUEL SYSTEMS

CONTENTS

page

2.2L TURBO III MULTI-PORT FUEL INJECTION—

GENERAL DIAGNOSIS

. . . . . . . . . . . . . . . . . 95

2.2L TURBO III MULTI-PORT FUEL INJECTION—

ON-BOARD DIAGNOSTICS

. . . . . . . . . . . . . 100

2.2L TURBO III MULTI-PORT FUEL INJECTION—

SERVICE PROCEDURES

. . . . . . . . . . . . . . . 107

2.2L TURBO III MULTI-PORT FUEL INJECTION—

SYSTEM OPERATION

. . . . . . . . . . . . . . . . . . 83

2.2L/2.5L SINGLE POINT FUEL INJECTION—

GENERAL DIAGNOSIS

. . . . . . . . . . . . . . . . . . 35

2.2L/2.5L SINGLE POINT FUEL INJECTION—

ON-BOARD DIAGNOSTICS

. . . . . . . . . . . . . . 41

2.2L/2.5L SINGLE POINT FUEL INJECTION—

SERVICE PROCEDURES

. . . . . . . . . . . . . . . . 48

2.2L/2.5L SINGLE POINT FUEL INJECTION—

SYSTEM OPERATION

. . . . . . . . . . . . . . . . . . 24

2.5L FLEXIBLE FUEL MULTI-PORT FUEL

INJECTION—GENERAL DIAGNOSIS

. . . . . . . 66

2.5L FLEXIBLE FUEL MULTI-PORT FUEL

INJECTION—ON-BOARD DIAGNOSTICS

. . . 70

2.5L FLEXIBLE FUEL MULTI-PORT FUEL

INJECTION—SERVICE PROCEDURES

. . . . . 77

2.5L FLEXIBLE FUEL MULTI-PORT FUEL

INJECTION—SYSTEM OPERATION

. . . . . . . 55

3.0L MULTI-PORT FUEL INJECTION—

GENERAL DIAGNOSIS

. . . . . . . . . . . . . . . . . 125

3.0L MULTI-PORT FUEL INJECTION—

ON-BOARD DIAGNOSTICS

. . . . . . . . . . . . . 130

3.0L MULTI-PORT FUEL INJECTION—

SERVICE PROCEDURES

. . . . . . . . . . . . . . . 138

3.0L MULTI-PORT FUEL INJECTION—

SYSTEM OPERATION

. . . . . . . . . . . . . . . . . 113

3.3L AND 3.8L MULTI-PORT FUEL INJECTION—

GENERAL DIAGNOSIS

. . . . . . . . . . . . . . . . . 157

3.3L AND 3.8L MULTI-PORT FUEL INJECTION—

ON-BOARD DIAGNOSTICS

. . . . . . . . . . . . . 162

3.3L AND 3.8L MULTI-PORT FUEL INJECTION—

SERVICE PROCEDURES

. . . . . . . . . . . . . . . 169

3.3L AND 3.8L MULTI-PORT FUEL INJECTION—

SYSTEM OPERATION

. . . . . . . . . . . . . . . . . 145

ACCELERATOR PEDAL AND THROTTLE

CABLE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

FUEL DELIVERY SYSTEM

. . . . . . . . . . . . . . . . . 3

FUEL TANKS

. . . . . . . . . . . . . . . . . . . . . . . . . . 14

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . 178

GENERAL INFORMATION

Throughout this group, references are made to a

particular vehicle by letter designation. A chart
showing the breakdown of these designations is in-
cluded in the Introduction Section at the front of this
service manual.

The Fuel System consists of the fuel tank, fuel

pump, fuel filter, throttle body, fuel injectors, fuel
tubes and vacuum tubes.

The Fuel Delivery System consists of the fuel

pump, fuel filter, fuel lines and fuel hoses.

The Fuel Tank Assembly consists of the fuel tank,

filler tube, a fuel gauge sending unit assembly and a
pressure-vacuum filler cap.

Also, the Evaporation Control System is part of the

fuel system. The evaporation control system is de-
signed to reduce the emission of fuel vapor into the
atmosphere.

The description and function of the Evaporation

Control System is found in Group 25 of this manual.

FUEL REQUIREMENTS

Your vehicle was designed to meet all emission

regulations and provide excellent fuel economy when
using high quality unleaded gasoline.

VEHICLES WITHOUT TURBOCHARGED
ENGINES

Use unleaded gasoline having a minimum octane

rating of 87.

VEHICLES WITH TURBOCHARGED
ENGINES—EXCEPT 16 VALVE 2.2L ENGINES

These vehicles will operate satisfactorily on both

regular unleaded gasoline having a minimum octane
rating or 87, and premium unleaded gasoline having
a minimum octane rating of 91. The use of premium
unleaded gasoline will improve performance.

VEHICLES WITH 2.2L 16 VALVE ENGINES

The use of premium unleaded gasoline having a

minimum octane of 91 is recommended. If premium
unleaded is not available, then unleaded gasoline

FUEL SYSTEMS

14 - 1

with a minimum octane of 87 may be used. However,
the use of lower octane gasoline will result in re-
duced performance.

FLEXIBLE FUEL AA-BODY VEHICLES

These vehicles will operate on either unleaded gas-

oline with a minimum posted octane of 87 or M85
fuel. M85 fuel is a mixture of 85 percent methanol
and 15 percent unleaded gasoline. The vehicle also
will operate on mixture of M85 and unleaded gaso-
line with a minimum posted octane of 87. Do not
use 100 percent methanol in these vehicles.

THE FOLLOWING IS APPLICABLE TO ALL
VEHICLES

Light spark knock at low engine speeds is not

harmful to your engine. However, continued heavy
spark knock at high speeds can cause damage and
should be reported to your dealer immediately. En-
gine damage resulting from operating with a heavy
spark knock may not be covered by the new vehicle
warranty.

In addition to using unleaded gasoline with the

proper octane rating, gasolines that contain deter-
gents, corrosion and stability additives are recom-
mended. Using gasolines that have these additives
will help improve fuel economy, reduce emissions,
and maintain vehicle performance. Generally, pre-
mium unleaded gasolines contain more additive than
regular unleaded.

Poor quality gasoline can cause problems such as

hard starting, stalling, and stumble. If you experi-
ence these problems, try another brand of gasoline
before considering service for the vehicle.

GASOLINE/OXYGENATE BLENDS

Some fuel suppliers blend gasoline with materials

that contain oxygen such as alcohol, MTBE (Methyl
Tertiary Butyl Ether) and ETBE (Ethyl Tertiary Bu-
tyl Ether). The type and amount of oxygenate used
in the blend is important.

The following are generally used in gasoline

blends:

Ethanol - (Ethyl or Grain Alcohol) properly

blended, is used as a mixture of 10 percent ethanol
and 90 percent gasoline. Gasoline blended with eth-
anol may be used in your vehicle.

Methanol - (Methyl or Wood Alcohol) is used in a

variety of concentrations when blended with un-
leaded gasoline. You may find fuels containing 3 per-
cent or more methanol along with other alcohols
called cosolvents.

Do not use gasolines containing Methanol.
Use of methanol/gasoline blends may result in

starting and driveability problems and damage criti-
cal fuel system components.

Problems that are the result of using methanol/gas-

oline blends are not the responsibility of Chrysler
Motors and may not be covered by the new vehicle
warranty.

MTBE/ETBE - Gasoline and MTBE (Methyl Ter-

tiary Butyl Ether) blends are a mixture of unleaded
gasoline blended and up to 15 percent MTBE. Gaso-
line and ETBE (Ethyl Tertiary Butly Ether) are
blends of gasoline and up to 17 percent ETBE. Gas-
oline blended with MTBE or ETBE may be used in
your vehicle.

Clean Air Gasoline
Many gasolines are now being blended that con-

tribute to cleaner air, especially in those areas of the
country where pollution levels are high. These new
blends provide a cleaner burning fuel and some are
referred to as reformulated gasoline.

In areas of the country where carbon monoxide lev-

els are high, gasolines are being treated with oxy-
genated

materials

such

ETBE,

MTBE

and

ethanol. The use of gasoline blended with these ma-
terials also contributes to cleaner air.

Chrysler Corporation supports these efforts toward

cleaner air and recommends that you use these gas-
olines as they become available.

Materials Added to Fuel
Indiscriminate use of fuel system cleaning agents

should be avoided. Many of these materials intended
for gum and varnish removal may contain active sol-
vents of similar ingredients that can be harmful to
fuel system gasket and diaphragm materials.

14 - 2

FUEL SYSTEMS

FUEL DELIVERY SYSTEM

INDEX

page

Chassis Fuel Tubes

. . . . . . . . . . . . . . . . . . . . . . 11

Flexible Fuel Components

. . . . . . . . . . . . . . . . . . . 3

Fuel Filter—All Vehicles

. . . . . . . . . . . . . . . . . . . . 9

Fuel Hoses, Clamps, and Quick Connect Fittings

. 10

Fuel Pump Assembly

. . . . . . . . . . . . . . . . . . . . . . 5

Fuel Pump Module Installation

. . . . . . . . . . . . . . . 9

Fuel Pump Module Removal

. . . . . . . . . . . . . . . . . 8

Fuel Pump Pressure Test—2.2L/2.5L TBI and 3.0L

MPI Engines

. . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Fuel Pump Pressure Test—All Except 2.2L/2.5L

TBI and 3.0L MPI

. . . . . . . . . . . . . . . . . . . . . . . 6

Fuel Pump Strainer Service

. . . . . . . . . . . . . . . . . . 9

Fuel System Pressure

. . . . . . . . . . . . . . . . . . . . . . 6

Fuel System Pressure Release Procedure—

2.2L/2.5L TBI

. . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Fuel System Pressure Release Procedure—3.0L

. . 5

Fuel System Pressure Release Procedure—Except

2.2L/2.5L TBI and 3.0L

. . . . . . . . . . . . . . . . . . . 4

General Information

. . . . . . . . . . . . . . . . . . . . . . . . 3

Identifying Flexible Fuel Components

. . . . . . . . . . 3

Mechanical Malfunctions

. . . . . . . . . . . . . . . . . . . . 8

Methanol Concentration Sensor—Flexible Fuel

AA-Body

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Service Precautions for Flexible Fuel Vehicles

. . . . 3

GENERAL INFORMATION

Beginning this model year, Chrysler began produc-

ing AA-Body vehicles designed to operate on a mix-
ture of gasoline and methanol. These automobiles are
referred to as Flexible Fuel vehicles.

Flexible fuel vehicles can operate on a mixture of

up to 85 percent methanol, 15 percent unleaded gas-
oline. These vehicles also operate on mixtures con-
taining a lower percentage of methanol or just pure
unleaded gasoline.

In many cases, the procedures for servicing flexible

fuel components is identical to gasoline only compo-
nents. Refer to the particular Service Procedure in
this section. If the service procedure for flexible fuel
component differs from a gasoline only component,
the title of each service procedure identifies the ap-
plication.

SERVICE PRECAUTIONS FOR FLEXIBLE FUEL
VEHICLES

Methanol is more toxic than gasoline. Always re-

lease fuel system pressure before servicing fuel sys-
tem components and wear methanol resistant gloves
and eye protection.

Avoid breathing methanol vapors or ingesting

methanol. Headaches, dizziness and even uncon-
sciousness could result from breathing these vapors.
Serious injury, blindness and even death could result
from ingesting methanol.

Methanol vapors are extremely flammable and can

travel along the ground. Service vehicles in well ven-
tilated areas and avoid ignition sources. Never
smoke while servicing the vehicle.

Do not allow methanol to contact skin. Prolonged

contact with methanol can cause dry skin or an al-
lergic skin reaction. Also, prolonged contact could re-
sult in absorption through the skin.

IDENTIFYING FLEXIBLE FUEL COMPONENTS

Flexible Fuel vehicles have unique methanol com-

patible fuel system components. Chrysler identifies
methanol compatible components that could be phys-
ically interchanged with gasoline only parts by color-
ing them green or applying a green label or tag to
them. Even though they may appear physically iden-
tical, components for gasoline only vehicles must not
be used on flexible fuel vehicles.

FLEXIBLE FUEL COMPONENTS

Flexible fuel AA-body vehicles uses many unique

fuel system components. The unique parts are green
in appearance or have a green tag or label attached
to them. While components used on gasoline only ve-
hicles may look similar or identical, they cannot be
used on flexible fuel vehicles. When servicing a com-
ponent, always use an original equipment or equiva-
lent flexible fuel replacement.

The fuel system of flexible fuel AA-body vehicles

have the following unique components.
• Fuel pump module

• Fuel level sensor

• Fuel gauge (gauge cluster).

• Fuel tank

• Fuel pressure regulator (including O-rings)

• Fuel rail

• Fuel injectors (including O-rings)

• Fuel tubes

• Fuel filter

• EVAP canister

• Fuel filler cap

• Fuel filler tube

• Pressure relief/Rollover valve

• All fuel system and emission system hoses and
tubes

FUEL SYSTEMS

14 - 3

INSTRUMENT PANEL CLUSTER
IDENTIFICATION—FLEXIBLE FUEL AA-BODY

Flexible fuel A-Body vehicles use a unique gauge

cluster. To identify the cluster, remove it from the
instrument panel and check the number on the tag
on the top. If the part number matches the number
in the parts book for flexible fuel A-bodies, the vehi-
cle was built with the correct cluster. Refer to Group
8E, Instrument Panel and Gauges, for cluster re-
moval and installation.

METHANOL CONCENTRATION SENSOR—FLEXIBLE
FUEL AA-BODY

The methanol concentration sensor contains a mi-

croprocessor that determines the percentage of gaso-
line and methanol in the fuel system. From the
methanol concentration sensor input, the powertrain
control module (PCM) determines the amount of
methanol in the fuel. The vehicle can operate on a
mixtures up to 85 percent methanol, 15 percent gas-
oline.

The methanol concentration sensor output voltages

varies with the percent of methanol in the fuel sys-
tem. The sensor output voltage (input for PCM)
ranges from 0.5 volts for pure gasoline to 4.75 volts
for 85 percent methanol. For two seconds at key ON
when the operator starts the vehicle, the sensor cal-
ibrates the PCM. During the calibration period the
sensor sends 4.45 volts to the PCM as a correction
factor.

The methanol concentration sensor has a built-in

shutdown capability. If the sensor shuts down, it de-
faults to the previous learned value (output voltage
based on methanol percentage of fuel).

The methanol concentration sensor attaches to a

bracket at the rear of the fuel tank, next to the fuel
filler tube (Fig. 1).

REMOVAL

WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
WHEN

SERVICING

FLEXIBLE

FUEL

VEHICLES,

WEAR METHANOL RESISTANT GLOVES AND EYE
PROTECTION AND AVOID BREATHING FUMES. DO
NOT ALLOW METHANOL/GASOLINE MIXTURES TO
CONTACT SKIN. SERVICE VEHICLES IN WELL VEN-
TILATED AREAS AND AVOID IGNITION SOURCES.
NEVER SMOKE WHILE SERVICING THE VEHICLE.

Quick connect fittings attach the fuel tubes to the

methanol concentration sensor (Fig. 1)

(1) Release fuel system pressure. Refer to the Fuel

System Pressure Release Procedure.

(2) Disconnect the fuel tubes from sensor. Refer to

Quick Connect Fittings in this section.

(3) Disconnect electrical connector from sensor.
(4) Remove mounting nuts.

INSTALLATION

(1) Place sensor on bracket. Tighten mounting nut.
(2) Attach electrical connector to sensor.
(3) Connect fuel tubes to sensor. Refer to Quick

Connect Fittings in this section.

FUEL SYSTEM PRESSURE RELEASE
PROCEDURE—EXCEPT 2.2L/2.5L TBI AND 3.0L

WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
WHEN

SERVICING

FLEXIBLE

FUEL

VEHICLES,

(1) Disconnect negative cable from battery.
(2) Remove fuel filler cap.
(3) Remove the protective cap from the fuel pres-

sure test port on the fuel rail (Fig. 2).

(4) Place the open end of fuel pressure release

hose, tool number C-4799-1, into an approved gaso-
line container or a container approved for gasoline/
methanol mixtures. Connect the other end of hose
C-4799-1 to the fuel pressure test port (Fig. 3). Fuel
pressure will bleed off through the hose into the gas-
oline container. Fuel gauge C-4799-A contains hose
C-4799-1.

FUEL SYSTEM PRESSURE RELEASE
PROCEDURE—2.2L/2.5L TBI

CAUTION: Before servicing the fuel pump, fuel
lines, fuel filter, throttle body, or fuel injector, re-
lease fuel system pressure.

Fig. 1 Methanol Concentration Sensor

14 - 4

FUEL SYSTEMS

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