Content .. 216 217 218 219 ..

Chrysler PT Cruiser. Manual - part 218

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.

WARNING: NO SPARKS, OPEN FLAMES OR SMOK-
ING. RISK OF POISONING FROM INHALING AND
SWALLOWING FUEL. RISK OF INJURY TO EYES
AND SKIN FROM CONTACT WITH FUEL. POUR
FUELS ONLY INTO SUITABLE AND APPROPRI-
ATELY MARKED CONTAINERS. WEAR PROTECTIVE
CLOTHING.

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

COVER - REMOVAL).

(3) Disconnect fuel rail pressure sensor and fuel

pressure solenoid electrical connectors (Fig. 5).

CAUTION: When slackening and tightening fuel
injection line union nuts, counter hold with wrench
at threaded connection. ON NO ACCOUNT exceed
the tightening torque at any time. Do NOT crimp or
bend lines.

NOTE: After removing lines, seal connections and
ensure cleanliness.

(4) Remove injector high pressure lines (Refer to

14 - FUEL SYSTEM/FUEL DELIVERY/FUEL LINES
- REMOVAL) (Fig. 5).

(5) Remove pressure line of high pressure pump

from rail (Fig. 5).

(6) Detach fuel return flow line to high pressure

pump at rail (Fig. 5).

(7) Detach fuel return flow line to fuel filter at fuel

rail (Fig. 5).

(8) Remove fuel rail mounting bolts and remove

fuel rail from cylinder head (Fig. 6).

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

WARNING: NO FIRE, FLAMES OR SMOKING. RISK
OF POISONING FROM INHALING OR SWALLOWING
FUEL. RISK OF INJURY TO EYES AND SKIN FROM
CONTACT WITH FUEL. POUR FUELS ONLY INTO
SUITABLE AND APPROPRIATELY MARKED CON-
TAINERS. WEAR PROTECTIVE CLOTHING.

(1) Position fuel rail to cylinder head. Tighten

bolts finger tight only (Fig. 6).

(2) Position and loosely install fuel return line

from fuel filter, with new seals to rail (Fig. 6).

(3) Connect high pressure line from pump to rail

at rail (Fig. 5). Tighten line finger tight only.

(4) Torque fuel rail bolts to 14 N·m (124 lbs.in.)

(Fig. 6).

(5) Tighten nut of high pressure line at fuel rail to

22N·m (194 lbs.in.).

(6) Tighten banjo bolt of fuel return line to fuel

rail to 20N·m (177 lbs.in.).

Fig. 6 FUEL RAIL MOUNTING BOLTS

1 - FUEL RAIL
2 - FUEL RAIL MOUNTING BOLTS

14 - 10

FUEL DELIVERY

FUEL RAIL (Continued)

CAUTION: Inspect sealing cones at the lines.
Replace as necessary. Ensure that all fuel pressure
lines are exactly located in original position.

(7) Install injector lines high pressure lines (Fig.

5). Tighten nut of pressure line to rail/injector to
22N·m (194 lbs.in.).

(8) Reconnect fuel rail pressure sensor and fuel

pressure solenoid electrical connectors (Fig. 5).

(9) 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

(10) Start engine and inspect for leaks.
(11) Install engine cover (Refer to 9 - ENGINE

COVER - INSTALLATION).

FUEL LINES

REMOVAL - HIGH PRESSURE LINES

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 -

REMOVAL).

CAUTION: Counterhold with wrench at threaded
connections of injectors. DO NOT EXCEED the
tightening torque in order to avoid also loosening
the threaded connection.

CAUTION: DO NOT crimp or bend lines.

NOTE: After removing injection lines, seal connec-
tions and ensure cleanliness.

(3) Unscrew union nuts of injection lines.
(4) Remove injection lines (Fig. 7).

INSTALLATION - HIGH PRESSURE LINES

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. 7 HIGH PRESSURE LINES AT INJECTORS -

TYPICAL

1 - HIGH PRESSURE LINE
2 - CYLINDER HEAD COVER
3 - FUEL RAIL

FUEL DELIVERY

14 - 11

FUEL RAIL (Continued)

(1) Loosen the fuel rail mounting bolts to install

lines free of stress.

CAUTION: Inspect sealing cone at lines. Replace if
compression points exist. Ensure lines are exactly
located.

(2) Position and install fuel lines (Fig. 7). Tighten

to 22N·m (195 lbs. in.) using a wrench to counterhold
at threaded connection.

(3) Tighten fuel rail to 14N·m (124 lbs. in.).
(4) 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

(5) Start engine and inspect for leaks.
(6) Install engine cover (Refer to 9 - ENGINE -

INSTALLATION).

FUEL TANK

DESCRIPTION

The fuel tank is made from High Density Polyeth-

ylene (HDPE) material with 2 permanently mounted
vent valves and a replaceable fuel tank vent filter. Its
main functions are for fuel storage and placement of
the fuel pump module (Fig. 8).

OPERATION

Fuel tanks pass a full 360 degree roll over test

without fuel leakage. To accomplish this, fuel and

vapor flow controls are required for all fuel tank con-
nections.

The fuel tank is equipped with two permanent vent

valves, mounted diagonally to the top of the fuel
tank. This allows the fuel tank to vent properly
regardless of driving angle, or when refueling.

A fuel tank vent filter is connected inline to the

fuel fill valve, and vapor valve, to reduce emissions of
fuel vapors into the atmosphere, when the tank is
being filled or venting due to thermal expansion.
This filter also prevents contaminants from entering
the fuel system through the vapor valves.

INLET CHECK VALVE

All vehicles have an inlet check valve on the inside

of the fuel tank at the filler inlet

The valve prevents fuel from splashing back on

customer during vehicle refueling. The valve is a
non-serviceable item.

Fig. 8 FUEL TANK

1 - FUEL TANK VENT FILTER
2 - FUEL SUPPLY LINE
3 - FUEL RETURN LINE
4 - FUEL TANK VENT VALVE
5 - FUEL PUMP MODULE
6 - FUEL TANK FILL VENT VALVE

14 - 12

FUEL DELIVERY

FUEL LINES (Continued)

FUEL PUMP MODULE

DESCRIPTION - FUEL PUMP MODULE

The fuel pump module is located in the fuel tank

and consists of a fuel pump, fuel contaminant filter-
ing screen, fuel reservoir and fuel tank level monitor-
ing devise. The fuel pump is a high pressure, high
flow pump regulated to 2.5 bar (36psi), in order to
maintain an adequate supply of fuel to the high pres-
sure injection pump (Fig. 9).

OPERATION

When the ECM senses the ignition switch in the

On, Crank or Run mode, battery positive voltage is
supplied from the ASD relay and the PDC to the fuel
pump relay. The ECM will also ground the fuel pump
relay driver at this time, closing the fuel pump relay
contacts, completing the fuel pump circuit to chassis
ground. If the ECM senses the ignition in the ON
position, without a engine crank signal for more than
30 seconds, it will open the fuel pump driver circuit,
turning off the fuel pump.

The regulated fuel pump, in On and Crank mode

will produce 0.4 to 1.5 bar (6 psi. to 22 psi.). In Run
mode the fuel pump will produce at least 2.5 bar (36
psi.) not to exceed 2.9 bar (42 psi.) to maintain con-
stant fuel pressure to the injection pump.

FUEL FILTER/FUEL HEATER

DESCRIPTION

The fuel filter assembly is mounted underhood to

the engine controller bracket on the dash panel and
incorporates a fuel heater element. The paper ele-
ment of the fuel filter protects the fuel injection
pump by removing contaminates from the fuel. The
fuel heater keeps the fuel at a suitable temperature
range to improve cold starting, cold engine drivability
and cold exhaust emissions. Integral to the fuel filter
assembly is a single spring diaphram fuel pressure
regulator used to maintain the fuel pressure at a
constant value under all driving conditions. The fuel
heater and fuel regulator are serviced along with the
housing as an assembly, where as the fuel filter
should be replaced every 20,000 km.

Fig. 9 FUEL PUMP MODULE

1 - FUEL SUPPLY
2 - FUEL PUMP MODULE
3 - FUEL GAGE SENDING UNIT FLOAT
4 - FUEL PUMP
5 - FUEL RETURN

Fig. 10 FUEL FILTER/FUEL HEATER

1 - FUEL FILTER
2 - FUEL SUPPLY TO INJECTION PUMP
3 - FUEL RETURN FROM INJECTION PUMP
4 - FUEL HEATER
5 - FUEL SUPPLY FROM FUEL TANK
6 - FUEL RETURN TO FUEL TANK
7 - FUEL PRESSURE REGULATOR

FUEL DELIVERY

14 - 13

Content .. 216 217 218 219 ..