Chrysler PT Cruiser. Manual - part 219

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - FUEL FILTER

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.

This diagnostic will test for a failing fuel pump or

restricted fuel filter.

(1) Disconnect the negative battery cable.
(2) Disconnect the fuel supply line to the fuel fil-

ter/fuel heater assembly, at the filter assembly.

NOTE: Obtain the correct Fuel Line Pressure Test
Adapter Tool Hose. Tool number 6539 is used for
5/16” fuel lines and tool number 6631 is used for
3/8”lines.

(3) Connect correct Fuel Line Pressure Test Adap-

tor Tool Hose between the disconnected fuel line and
filter/heater assembly (Fig. 11).

(4) Connect the 0-4.1bar (0-60 psi.) fuel pressure

gauge (from Gauge Set 5069) to the test port on the
appropriate Adaptor Tool.

(5) Connect negative battery cable.
(6) Crank or run engine and record the fuel pres-

sure reading.

(7) Turn off the ignition (fuel pressure should

begin to bleed down immediately).

(8) Disconnect negative battery cable.

WARNING: THERE MAY BE FUEL IN THE PRES-
SURE TEST ADAPTOR TOOL HOSE, WRAP SHOP
TOWELS AROUND HOSES TO CAPTURE ANY FUEL
SPILLAGE.

(9) Disconnect Fuel Line Pressure Adaptor Tool

Hose.

(10) Reconnect fuel tank supply line to fuel filter/

fuel heater assembly.

(11) Disconnect fuel supply line to injector pump,

at the fuel filter/fuel heater assembly (Fig. 12).

(12) Connect Fuel Line Pressure Test Adaptor Tool

Hose between the disconnected fuel line and filter/
heater assembly.

(13) Connect negative battery cable.
(14) Crank or run engine and record the fuel pres-

sure reading.

(15) Turn off the ignition.
(16) Disconnect negative battery cable.
(17) Reconnect the fuel supply line to the fuel fil-

ter/fuel heater.

Fig. 11 FUEL PRESSURE GAUGE

1 - FUEL FILTER/FUEL HEATER
2 - FUEL PRESSURE TEST HOSE
3 - FUEL PRESSURE GAUGE
4 - CONNECT TO FUEL TANK SUPPLY LINE

Fig. 12 FUEL PRESSURE GAUGE

1 - FUEL FILTER/FUEL HEATER
2 - FUEL PRESSURE GAUGE
3 - FUEL LINE PRESSURE TEST ADAPTOR HOSE
4 - CONNECT TO INJECTOR PUMP FUEL SUPPLY LINE

14 - 14

FUEL DELIVERY

FUEL FILTER/FUEL HEATER (Continued)

Inspect fuel lines and fuel tank for leaks and dam-

age, replace the fuel pump module if the first pres-
sure reading test did not obtain 1.5bar (22 psi.).
Retest system after repair.

Replace the fuel filter if the pressure difference

between test one and test two is more than 0.5bar (8
psi.).

DIAGNOSIS AND TESTING - FUEL HEATER

CONDITION

POSSIBLE CAUSES

CORRECTION

Fuel Heater Inoperative

No ignition positive voltage to heater.

Open or Shorted ignition
positive voltage circuit.

Poor connector terminal end
connection.

No fuel heater ground.

Open or Shorted ground circuit.

Poor connector terminal end
connection.

Open fuel heater element.

Replace fuel filter/fuel heater
assembly.

REMOVAL

WARNING: THERE IS FUEL PRESENT IN THE FIL-
TER HOUSING. REMOVE HOSES, AND HANDLE
THE FILTER HOUSING CAREFULLY TO REDUCE
SPLASH.

NOTE: Use a shop towel to capture any residual
fuel spillage during this procedure.

(1) Disconnect negative battery cable.
(2) Disconnect fuel supply line form fuel tank.
(3) Disconnect fuel supply line to injection pump.
(4) Disconnect both fuel return lines from pressure

regulator.

(5) Disconnect fuel heater electrical connector.
(6) Remove the right ECM mounting bracket to

dash panel screws.

(7) Carefully pull back on the ECM mounting

bracket and remove fuel filter housing retaining
screws and filter housing from vehicle.

REMOVAL - FUEL FILTER

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.

NOTE: Use a shop towel to capture any residual
fuel spillage during this procedure.

(2) Unscrew the fuel filter element from the top of

the housing and discard (Fig. 10).

Fig. 13 FUEL FILTER HOUSING ASSEMBLY

1 - FUEL FILTER
2 - FUEL FILTER HOUSING
3 - FUEL HEATER
4 - ECM BRACKET

FUEL DELIVERY

14 - 15

FUEL FILTER/FUEL HEATER (Continued)

INSTALLATION

NOTE: Use shop towels to capture any residual fuel
spillage during this procedure.

(1) Position the fuel filter housing against ECM

mounting bracket and install screws. Tighten screws
to 28N·m (250 lbs.in.). (Fig. 13).

(2) Position and install the ECM bracket. Tighten

ECM mounting bracket retaining screws to 12 N·m.
(115 lbs.in.).

(3) Connect fuel heater electrical connector.
(4) Connect both fuel return lines to pressure reg-

ulator.

(5) Connect fuel supply line to injector pump.
(6) Connect fuel supply line to fuel tank.
(7) Connect negative battery cable.

(8) Start engine and inspect for leaks.

INSTALLATION - FUEL FILTER

(1) Lubricate new fuel filter element seal with

clean diesel fuel and screw into housing.

(2) Torque fuel filter element to 35N·m (310 lbs.

in.).

(3) Connect negative battery cable.
(4) Start engine and inspect for leaks.

14 - 16

FUEL DELIVERY

FUEL FILTER/FUEL HEATER (Continued)

FUEL INJECTION

TABLE OF CONTENTS

page

FUEL INJECTION

STANDARD PROCEDURE - TESTING FUEL

INJECTORS

. . . . . . . . . . . . . . . . . . . . . . . . . . 17

ACCELERATOR PEDAL POSITION SENSOR

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 18

BOOST PRESSURE SENSOR

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 19

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . 19

DIAGNOSIS AND TESTING - BOOST

PRESSURE SENSOR

. . . . . . . . . . . . . . . . . . 19

CRANKSHAFT POSITION SENSOR

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 19

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . 19

FUEL INJECTOR

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 20

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . 20

STANDARD PROCEDURE

STANDARD PROCEDURE - CLEANING

FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . 21

STANDARD PROCEDURE - INJECTOR

CLASSIFICATION . . . . . . . . . . . . . . . . . . . . . 21

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 23

FUEL PRESSURE SENSOR

DESCRIPTION

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

OPERATION

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

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 25

INTAKE AIR TEMPERATURE SENSOR

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 25

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . 25

CAMSHAFT POSITION SENSOR

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 26

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . 26

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 26

MANIFOLD AIR FLOW (MAF) SENSOR

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 26

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . 26

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 27

FUEL PRESSURE SOLENOID

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 27

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . 27

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 29

SWIRL ACTUATOR

DESCRIPTION

DESCRIPTION - INTAKE MANIFOLD SWIRL

VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

DESCRIPTION - SWIRL VALVE ACTUATOR

SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . 30

OPERATION

OPERATION - INTAKE MANIFOLD SWIRL

VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

OPERATION - SWIRL ACTUATOR

SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . 30

FUEL INJECTION

STANDARD PROCEDURE - TESTING FUEL
INJECTORS

WARNING:

AVOID

ALL

CONTACT

WITH

FUEL

SPRAY. THE HIGH PRESSURE PUMP SUPPLIES
HIGH-PRESSURE

FUEL

EACH

INDIVIDUAL

INJECTOR

THROUGH

HIGH-PRESSURE

LINES.

FUEL UNDER THIS AMOUNT OF PRESSURE CAN
PENETRATE SKIN AND CAUSE PERSONAL INJURY.
WEAR SAFETY GOGGLES AND ADEQUATE PRO-
TECTIVE CLOTHING WHEN SERVICING FUEL SYS-
TEM.

NOTE: The fuel pump pressure must be 1.5 bar (22
psi.), and the engine must be at operating tempera-
ture 80°C (176°F).

(1) Run the engine until operating temperature is

obtained.

(2) Turn OFF the ignition.
(3) Disconnect the fuel injector return hose at the

return hose fitting directly below the fuel pressure
solenoid (Fig. 1).

(4) Block off fuel return fitting at the fuel rail.
(5) Place the fuel return hose into a suitable con-

tainer.

(6) Start the engine and measure the amount of

return fuel into the container for one minute at idle.

FUEL INJECTION

14 - 17

Content .. 217 218 219 220 ..