Content .. 219 220 221 222 ..

Chrysler PT Cruiser. Manual - part 221

If an injector is replaced, it is then necessary to

assign the classification number to the corresponding
cylinder with the DRBIII

t in the control module.

INJECTOR CLASSIFICATION PROCEDURE

(1) Turn ignition switch “ON”.
(2) Using a DRB III

t and select ENGINE then

MISCELLANEOUS.

(3) Select LEARN INJECTORS.
(4) Using the up and down arrows, scroll to the

appropriate injector.

(5) Using the right and left arrows, set injector to

proper classification.

(6) Once injectors are classified, cycle ignition to

complete.

REMOVAL

WARNING: HIGH-PRESSURE FUEL LINES DELIVER
FUEL UNDER EXTREME PRESSURE FROM THE
INJECTION

PUMP

THE

INJECTORS.

THIS

MAYBE AS HIGH AS 1600BAR (23,200PSI). USE
EXTREME CAUTION WHEN INSPECTING FOR HIGH-
PRESSURE

FUEL

LEAKS.

FUEL

UNDER

THIS

AMOUNT OF PRESSURE CAN PENETRATE SKIN
CAUSING PERSONAL INJURY OR DEATH. INSPECT
HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF
CARDBOARD. WEAR SAFETY GOGGLES AND ADE-
QUATE PROTECTIVE CLOTHING WHEN SERVICING
FUEL SYSTEM.

CAUTION: PAY CLOSE ATTENTION TO THE FOL-
LOWING POINTS WHEN REMOVING FUEL INJEC-
TORS:

•

Injectors MUST be removed only using the spe-

cial tools provided for this purpose.

•

Injectors MUST NOT be disassembled.

•

Before cleaning injector recesses, seal all

injector holes in the injector recesses with a pin.

•

Clean all injector recesses in the cylinder head

with a non-woven cloth and then a cylinder brush.

•

Carefully clean sealing surfaces of injector

recesses with the round brush. DO NOT us a power
brush.

(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE

COVER - REMOVAL).

(3) Disconnect fuel injector supply line from injec-

tor and fuel rail and remove from engine (Fig. 9)
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
FUEL LINES - REMOVAL).

NOTE: If injectors are tight and cannot be removed
by hand, remove with special tools #8937 slide
hammer and #8938 extraction claw (Fig. 10).

(4) Remove fuel injector retaining bolt and tension-

ing claw (Fig. 10).

(5) Remove fuel injector from cylinder head (Fig.

10).

Fig. 8 INJECTOR CLASSIFICATION MARKINGS

Fig. 9 FUEL INJECTOR AND GLOW PLUG

LOCATIONS

1 - FUEL INJECTORS
2 - GLOW PLUGS
3 - FUEL RAIL
4 - HIGH PRESSURE FUEL LINE

14 - 22

FUEL INJECTION

FUEL INJECTOR (Continued)

INSTALLATION

WARNING: HIGH-PRESSURE FUEL LINES DELIVER
FUEL UNDER EXTREME PRESSURE FROM THE
INJECTION

PUMP

THE

INJECTORS.

THIS

MAYBE AS HIGH AS 1600BAR (23,200PSI). USE
EXTREME CAUTION WHEN INSPECTING FOR HIGH-
PRESSURE

FUEL

LEAKS.

FUEL

UNDER

THIS

Fig. 10 FUEL INJECTOR REMOVAL/INSTALLATION - TYPICAL

1 - INJECTOR DRAIN TUBES
2 - RETAINING CLIP
3 - INJECTOR HIGH PRESSURE LINE
4 - INJECTOR SEAL

5 - FUEL INJECTOR
6 - TENSIONING CLAW
7 - SPECIAL TOOLS #8938 AND #8937

FUEL INJECTION

14 - 23

FUEL INJECTOR (Continued)

CAUTION: PAY CLOSE ATTENTION TO THE FOL-
LOWING POINTS WHEN INSTALLING FUEL INJEC-
TORS.

•

Blow out injector recesses, clean again with

non-woven cloth and then cover over. Fiber resi-
dues from non-woven cloth ARE NOT permissible.

•

Carefully carry out a visual inspection of the

sealing surfaces of the injector recesses.

•

The length of the round brush can be adjusted

and should be approximately 3mm for cleaning the
seal seat. Optimal cleaning is achieved only if a
brush with a flat surface is used. If necessary the
surface of the brush can be ground flat on a grind-
ing stone.

•

ALWAYS replace the seals which seal off the

injectors at the cylinder head to the combustion
chamber. It is important that no grease gets onto
the seal. Any impurities on the seal, on the sealing
surfaces at the injector and cylinder head as a
result of combustion residue or similar are abso-
lutely impermissible.

•

The screws attaching the injectors must always

be replaced. The screws must screw in easily, if
not, clean the threaded whole with an appropriate
thread tap.

•

The tip of the injector nozzle MUST NOT be

cleaned with a wire brush. Use a non-woven cloth.

•

Clean entire injector with a non-woven cloth.

•

Fiber residues from a non-woven cloth are not

permissible.

•

Apply a thin film of special grease to the injec-

tor stems.

•

Remove the pin in the nozzle holes with the

extension.

(1) Clean injectors and recesses (Refer to 14 -

FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - STANDARD PROCEDURE).

(2) Coat injector body with anti seize lubricant and

install injectors with new seals (Fig. 10).

(3) Install tensioning claw with new fastener (Fig.

10). Torque in two stages, 7N·m (62 lbs.in.) then 90°.

NOTE:

drain

tube

locking

clips

have

been

removed from injectors, the clips must be replaced.

(4) Connect fuel drain tubes at injectors (Fig. 10).
(5) Install high pressure fuel lines from rail to

injectors (Fig. 10) (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/FUEL LINES - INSTALLATION).

(6) Connect injector electrical connectors.
(7) Connect negative battery cable.

WARNING: HIGH-PRESSURE FUEL LINES DELIVER
FUEL UNDER EXTREME PRESSURE FROM THE
INJECTION

PUMP

THE

INJECTORS.

THIS

MAYBE AS HIGH AS 1600BAR (23,200PSI). USE
EXTREME CAUTION WHEN INSPECTING FOR HIGH-
PRESSURE

FUEL

LEAKS.

FUEL

UNDER

THIS

(8) Start engine and check for leaks.
(9) Install engine cover (Refer to 9 - ENGINE

COVER - INSTALLATION).

FUEL PRESSURE SENSOR

DESCRIPTION

The fuel pressure sensor monitors and passes on

the current rail pressure to the control module (Fig.
11). The non-constant system pressure influences the
position of the sensor diaphragm which alters the
sensors electrical resistance.

OPERATION

The rail pressure sensor measures the current rail

pressure and supplies an appropriate voltage signal
to the Engine Control Module (ECM). The pressure
control valve is then actuated by the ECM through a
control loop until the desired rail pressure is reached.

Fig. 11 FUEL RAIL AND FUEL PRESSURE SENSOR

LOCATIONS

1 - FUEL PRESSURE SENSOR
2 - FUEL RAIL

14 - 24

FUEL INJECTION

FUEL INJECTOR (Continued)

REMOVAL

WARNING: HIGH-PRESSURE FUEL LINES DELIVER
FUEL UNDER EXTREME PRESSURE FROM THE
INJECTION

PUMP

THE

INJECTORS.

THIS

MAYBE AS HIGH AS 1600BAR (23,200PSI). USE
EXTREME CAUTION WHEN INSPECTING FOR HIGH-
PRESSURE

FUEL

LEAKS.

FUEL

UNDER

THIS

(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE

COVER - REMOVAL).

(3) Disconnect fuel pressure sensor electrical con-

nector (Fig. 11).

(4) Remove fuel pressure sensor from fuel rail (Fig.

11).

INSTALLATION

WARNING: HIGH-PRESSURE FUEL LINES DELIVER
FUEL UNDER EXTREME PRESSURE FROM THE
INJECTION

PUMP

THE

INJECTORS.

THIS

MAYBE AS HIGH AS 1600BAR (23,200PSI). USE
EXTREME CAUTION WHEN INSPECTING FOR HIGH-
PRESSURE

FUEL

LEAKS.

FUEL

UNDER

THIS

(1) Install fuel pressure sensor into fuel rail (Fig.

11).

(2) Connect fuel pressure sensor electrical connec-

tor (Fig. 11).

(3) Install engine cover (Refer to 9 - ENGINE

COVER - INSTALLATION).

(4) Connect negative battery cable.

INTAKE AIR TEMPERATURE
SENSOR

DESCRIPTION

This sensor is used to monitor the intake air tem-

perature (Fig. 12).

OPERATION

The intake air temperature sensor is a negative

temperature coefficient (NTC) thermistor (resistance
varies with temperature). This means at cold air
temperature its resistance is high, so the voltage sig-
nal will be high. As intake air temperature increases,
sensor resistance decreases and the signal voltage
will be low. This allows the sensor to provide an ana-
log voltage signal (0.2-4.8 volts) to the ECM.

Fig. 12 SENSOR LOCATIONS

1 - BOOST PRESSURE SENSOR
2 - CRANKSHAFT POSITION (CKP) SENSOR
3 - INTAKE AIR TEMPERATURE SENSOR

FUEL INJECTION

14 - 25

FUEL PRESSURE SENSOR (Continued)

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