Chrysler Cirrus, Dodge Stratus, Plymouth Breeze Haynes. Manual — part 18
4-2
Chapter 4 Fuel and exhaust systems
2.3 The fuel pump module electrical connector is located in the
trunk, under the mat near the base of the left shock tower
3.4 On four-cylinder engines, connect a fuel pressure gauge to
the fuel rail at the test port
2
Fuel pressure relief procedure
Refer to illustration 2.3
Warning: Gasoline is extremely flammable,
so take extra precautions when you work on
any part of the fuel system. Don't smoke or
allow open flames or bare light bulbs near the
work area, and don't work in a garage where
a natural gas-type appliance (such as a water
heater or a clothes dryer) with a pilot light is
present. Since gasoline is carcinogenic, wear
latex gloves when there's a possibility of
being exposed to fuel, and if you spill any on
your skin, rinse it off immediately with soap
and water. Mop up any spills immediately and
do not store fuel-soaked rags where they
could ignite. The fuel system is under con-
stant pressure, so, if any fuel lines are to be
disconnected, the pressure must be relieved
first. When you perform any kind of work on
the fuel system, wear safety glasses and have
a Class B type fire extinguisher on hand.
1
Remove the fuel filler cap to relieve the
fuel tank pressure.
2
Working inside the trunk, fold back the
trunk mat near the base of the left shock
tower.
3
Locate the fuel pump electrical connec-
tor and disconnect it from the wiring harness
(see illustration).
4
Next, start the engine and allow it to run
until it stops. This should only take a few sec-
onds. Crank the engine again, to ensure the
fuel pressure is completely relieved. Before
working on any part of the fuel system, dis-
connect the negative battery cable from the
ground stud on the left shock tower (see
Chapter 5, Section 1).
5
Even after the fuel pressure has been
relieved, always lay a shop towel over any
fuel connection that is to be separated to
absorb the residual fuel that will leak out.
6
When you are finished working on the
fuel system, reconnect fuel pump electrical
connector to the wiring harness. Turn the
ignition key to the ON position a few times to
pressurize the system and check the serviced
area for leaks.
7
Install the fuel filler cap and tighten it
securely. Note: If the fuel filler cap seal allows
the fuel tank pressure to escape because of a
damaged seal or it has not been tightened
sufficiently, the CHECK ENGINE light will illu-
minate on the instrument panel.
3
Fuel pump/fuel pressure
regulator - check
Warning: Gasoline is extremely flammable,
so take extra precautions when you work on
any part of the fuel system (see the Warning
in Section 2).
Note 1: These vehicles are equipped with a
"returnless" fuel system in which the fuel
pressure regulator is part of the fuel pump
module and located inside the fuel tank.
Note 2: The fuel pump will operate as long as
the engine is cranking or running and the
PCM is receiving ignition reference pulses
from the electronic ignition system. If there
are no reference pulses, the fuel pump will
shut off after approximately 1 second.
Note 3: To perform the fuel pressure check,
you will need to obtain a fuel pressure gauge
and adapter set (fuel line fittings). On V6
engines, the fuel supply line is not equipped
with a fuel pressure test port (Schrader valve
fitting). A special fuel pressure test adapter
(factory tool No. 6539 or equivalent) must be
installed between the fuel supply line and the
fuel rail.
Preliminary check
Note: On all models, the fuel pump is located
inside the fuel tank (see Section 7).
1
If you suspect insufficient fuel delivery,
first inspect all fuel lines to ensure that the
problem is not simply a leak in a line.
2
Set the parking brake and remove the
fuel filler cap. Have an assistant turn the igni-
tion switch to the ON position while you listen
at the fuel filler neck opening. You should
hear a "whirring" sound, lasting for a couple
of seconds. Start the engine. The whirring
sound should now be continuous (although
harder to hear with the engine running). If
there is no sound, either the fuel pump fuses,
fuel pump, fuel pump relay, automatic shut-
down (ASD) relay or related circuits are
defective (proceed to Step 15).
System pressure check
Refer to illustrations 3.4 and 3.5
3
Perform the fuel pressure relief proce-
dure (see Section 2).
4
On four-cylinder engines, remove the
cap from the fuel pressure test port (Schrader
valve fitting) on the fuel rail and attach a fuel
pressure gauge (see illustration).
5
On V6 engines, the fuel supply line is not
equipped with a fuel pressure test port
(Schrader valve fitting). A special fuel pres-
sure test adapter (factory tool No. 6539 or
equivalent) must be installed between the fuel
supply line and the fuel rail. Disconnect the
fuel supply line from the fuel rail (see Sec-
tion 4) and install the fuel pressure test
adapter between the supply line and the fuel
rail (see illustration). Attach a fuel pressure
gauge to the test adapter fitting.
6
Start the engine and observe the pres-
sure reading on the gauge. Compare it with
the pressure listed in this Chapter's Specifi-
cations.
7
If the fuel pressure is higher than speci-
fied, check for a kinked or restricted fuel line
between the fuel filter and fuel pump module.
If the line is OK, replace the fuel pressure reg-
ulator (see Section 14).
8
If the fuel pressure is lower than speci-
fied, replace the fuel filter (see Section 15)
and perform the pressure check again. If it's
still low, remove the fuel pump module (see
Section 7) and inspect the fuel inlet strainer
for obstructions. If it's clogged, replace the
strainer. If the strainer is OK, replace the fuel
pump.
9
If there is no fuel pressure, check the
fuel pump, ASD and fuel pump relays as out-
li ned below.
10
Next, verify that the system holds pres-
sure. Note the fuel pressure with the engine
Chapter 4 Fuel and exhaust systems
4-3
3.5 On V6 engines, a special fuel pressure test adapter must be
installed between the fuel supply line and the fuel rail
125015-4-3.17
HAYNES
3.17 Fuel pump module electrical connector (body harness side)
Fuel pump (positive feed)
Fuel level sending unit (signal)
Fuel pump (ground)
Fuel level sending unit (ground)
1
2
3
4
running, then turn off the engine and observe
the reading on the fuel pressure gauge. The
fuel pressure should remain constant for a
minimum of one minute. A drop of more than
5 psi in one minute indicates an unaccept-
able leak in the system. If the pressure drop
is unacceptable, first visually inspect the sys-
tem for obvious leaks, especially at the quick
connect fittings.
11
If there aren't any obvious leaks, the fuel
is escaping either from one or more of the
fuel injectors or the fuel pressure regulator.
12
On four-cylinder engines, to perform the
following check it is necessary to install the
special fuel pressure test adapter (factory
tool No. 6539 or equivalent) between the fuel
rail and the fuel supply line. Perform the fuel
relief procedure (see Section 2) and install the
adapter and gauge set-up.
13
To determine where the fuel system is
leaking, pressurize the fuel system. With the
engine OFF, isolate the fuel injectors by
pinching off the rubber hose on the special
fuel pressure test adapter (factory tool No.
6539 or equivalent) between the fuel pressure
gauge and the fuel supply line. Observe the
reading on the fuel pressure gauge. If the fuel
pressure bleeds down there is a leak at one
or more of the injectors. Refer to Section 16
for further testing and replacement proce-
dures.
14 If the pressure remains constant, the
fuel injectors are OK and the fuel pressure
regulator must be replaced (see Section 14).
After the pressure tests are complete, per-
form the fuel pressure relief procedure (see
Section 2), remove the fuel pressure gauge
and adapter (if used) and assemble the
quick-connect fittings (see Section 4).
Component checks
Note: The fuel pressure regulator check is part
of the system pressure check (see above).
Fuel pump
Refer to illustration 3.17
15 If you cannot hear the fuel pump oper-
ate when energized (refer to preliminary
check above), use a test light or voltmeter to
verify the pump is receiving battery voltage.
16
Working inside the trunk, fold back the
trunk mat near the base of the left shock
tower. Locate the fuel pump 4-pin electrical
connector and disconnect it (see illustra-
tion 2.3).
17
Connect a test light or voltmeter to the
fuel pump positive feed and ground terminals
of the electrical connector (see illustration).
18
Have an assistant crank the engine -
battery voltage should be present at the elec-
trical connector. If voltage is present, replace
the fuel pump. If voltage is not present, check
the ASD and fuel pump relays (see below).
ASD and fuel pump relays
Refer to illustrations 3.20a, 3.20b, 3.21a,
3.21b, 3.23, 3.24 and 3.25
Note: The Automatic Shutdown (ASD) relay
and the fuel pump relay must both be tested
to insure proper fuel pump operation. Testing
procedures for the ASD relay and the fuel
pump relay are identical.
19
To access the relay box where the ASD
relay is located, remove air cleaner assembly
(see Section 9).
20
To test a relay, first remove it from its
location in the engine compartment Power
Distribution Center (PDC) (see illustrations).
4
3.20a The Automatic Shutdown relay (arrow) is located in the
Power Distribution Center under the square cover
3.20b The fuel pump relay (arrow) is located in the Power
Distribution Center under the rectangular cover
4-4
Chapter 4 Fuel and exhaust systems
TERMINAL LEGEND
NUMBER
I DENTIFICATION
30
COMMON FEED
85
COIL GROUND
86
COIL BATTERY
87
NORMALLY OPEN
87A
NORMALLY CLOSED
TERMINAL LEGEND
NUMBER
IDENTIFICATION
30
COMMON FEED
85
COIL GROUND
86
COIL BATTERY
87
NORMALLY OPEN
87A
NORMALLY CLOSED
3.21a ASD and fuel pump relay terminal identification
(rectangle type)
3.21b ASD and fuel pump relay terminal identification
(square type)
21
Verify that there is battery voltage at the
terminal in the PDC that corresponds with
terminal 30 of the relay (see illustrations).
This terminal should have voltage present at
all times. Now check the terminal in the PDC
that corresponds with terminal 86 on the
relay - it should have voltage present only
with the ignition key in the ON position.
22 If there is no voltage, check the fuel
pump fuses in cavities 8 and 10 in the PDC. If
voltage is not present at the fuse, check the
wiring and connectors to the PDC for a short,
broken wire or a bad connection.
23
Next, check relay operation by connect-
ing the probes of an ohmmeter to terminals
86 and 85 and measure the resistance. There
should be approximately 75 ohms resistance
(see illustration).
24
Now connect the ohmmeter probes to
terminals 30 and 87A and check for continu-
ity. Continuity should be present (see illus-
tration).
25
Check for continuity between terminals
30 and 87 (see illustration). There should be
no continuity.
26
Next, with the ohmmeter still connected
to relay terminals 87 and 30, use jumper
wires to connect the relay to the battery.
Connect the battery positive terminal to relay
terminal 86 and the battery negative terminal
to relay terminal 85. Continuity should exist
between terminals 87 and 30 when terminals
86 and 85 are energized. If continuity is not
present, replace the relay.
4
Quick-connect fittings and fuel
li nes - disassembly, assembly
and replacement
Warning: Gasoline is extremely flammable,
so take extra precautions when you work on
any part of the fuel system (see the Warning
in Section 2).
General information
1
Always perform the fuel pressure relief
procedure (see Section 2) before servicing
fuel lines or fittings.
2
The fuel supply and vapor lines extend
from the fuel tank to the engine compartment.
The lines are constructed of steel, plastic and
rubber. They are secured to the underbody
with clips and brackets. These lines should be
inspected for leaks, kinks and dents anytime
the vehicle is raised for service.
3
If evidence of dirt is found in the fuel
system or fuel filter during service, the
affected line should be disconnected and
blown out. Check the fuel inlet strainer on the
fuel pump module for blockage or contami-
nation (see Section 14).
Quick-connect fittings
4
Chrysler uses three different types of
quick-connect fittings to join various fuel
li nes and components. The first type uses a
single-tab retainer, the second type a two-
tab retainer and the third type incorporates a
plastic retainer ring (usually black in color)
which connects/disconnects much like a
common compressed air hose fitting. Some
are equipped with safety latch clips. The fit-
tings are equipped with non-serviceable 0-
ring seals located in the female part of the fit-
ting. In the event the fitting or tubing
becomes damaged or develops a leak,
replace the entire fuel line/quick-connect fit-
ting as an assembly. Always use original
equipment parts, or parts that meet or
exceed the original equipment standards.
3.23 Measure the resistance between
terminals 86 and 85 - it should be
approximately 75 ohms
3.24 Measure the resistance between
terminals 30 and 87A - continuity
should be present
3.25 Check for continuity between
terminals 30 and 87 - there
should be no continuity
Chapter 4 Fuel and exhaust systems
4-5'
4.5a Cross-sectional view of a two-tab quick-connect
fuel line fitting
WINDOW
TAB (2)
4.5b When properly assembled, the tab ear and shoulder on
the male fitting should be visible in the window
Single and two-tab retainer fittings
Disassembly
Refer to illustrations 4.5a, 4.5b, 4.9a and 4.9b
5
These quick-connect fittings have one or
2 windows (depending on type) located in the
side(s) of the female fitting. When the male fit-
ting is inserted into the female, the tab(s) on
the male engage in the window(s) and lock the
fitting together (see illustrations).
6
Perform the fuel pressure relief proce-
dure (see Section 2).
7
Remove all fasteners, brackets or clips
securing the lines as applicable.
8
Clean the area around the fitting to
remove dirt and foreign debris.
9
Depress the retaining tab(s) on the
quick-connect fitting and pull it apart (see
illustrations). Note: The retaining tabs and
shoulder should remain on the metal fuel line
after separation.
Assembly
10
Clean the male part of the fitting and
li ghtly lubricate it with clean engine oil.
11
Position the retaining tab ears on the
tube so they align with the windows in the
female fitting and push them together. You
should hear the fitting snap into place as the
retaining tab ears lock into the windows.
12
Verify the fitting is properly fastened by
trying to pull the lines apart.
13
Secure the fuel line using any clips or
brackets as applicable.
14
Pressurize the system and check for
leaks.
Plastic retainer ring fittings
Disassembly
Refer to illustration 4.18
15
Perform the fuel pressure relief proce-
dure (see Section 2).
16
Remove all fasteners, brackets or clips
securing the lines as applicable.
17
Clean the area around the fitting to
remove dirt and foreign debris.
18
Grasp the male line and push it in
(towards the fitting). While applying pressure
on the male line, press the plastic retainer ring
into the female fitting and then pull the male
li ne from the female fitting (see illustration).
Note: The plastic retainer ring must be pushed
4.9b ... and separate the fitting - to
assemble it, lubricate the male end with a
small amount of clean engine oil, then push
the fitting together until it locks into place -
tug on it to ensure the connection is secure
into the female fitting squarely! If it gets
cocked, the fitting will be difficult to separate. If
necessary, use an open-end wrench applied to
the plastic retainer to assist in evenly pressing
it into the female fitting. The plastic retainer
ring should remain attached to the female fit-
ting after separation.
Assembly
19
Clean the male part of the fitting and
li ghtly lubricate it with clean engine oil.
20 Insert the male end into the female and
push them together (see illustration 4.18).
You should hear the retainer ring snap into
4.9a Depress the plastic tabs on
the male fitting .. .
I NSTALLATION
PLASTIC
RETAINER
4.18 Plastic retainer ring type quick-connect fitting removal and installation
4-6
Chapter 4 Fuel and exhaust
systems
5.6 Fuel tank drain plug (arrow)
FUEL PUMP
MODULE
5.9 Fuel pump module fuel line fittings
place as it locks the fitting together. Make
sure the retainer ring is fully extended after
assembly.
21
Verify the fitting is properly fastened by
trying to pull the lines apart.
22
Secure the fuel line using any clips or
brackets as applicable.
23
Pressurize the system and check for
leaks.
Fuel lines - replacement
Steel tubing
24 If replacement of a metal line is required,
disassemble the applicable quick-connect fit-
tings as described above and remove the line
from the vehicle. If the quick-connect fitting is
damaged or leaks, replace the affected sec-
tion of fuel line/quick-connect fittings as an
assembly.
25 If the quick-connect fittings are accept-
able, a new piece of steel tubing may be
spliced-in to replace a damaged section by
flaring the tubing ends and joining them with a
union. Use tubing that meets or exceeds orig-
inal equipment standards. Do not use copper
or aluminum tubing to replace steel tubing.
These materials cannot withstand normal
vehicle vibration. Do not use a rubber hose to
replace a damaged section of steel tubing!
26
When installing the replacement section
into the line, assemble the quick-connect fit-
tings first, then tighten the unions. Warning:
Metal lines must never be allowed to rub
against other components or each other. A
minimum of 1/4-inch clearance must be
maintained to prevent contact unless it is
properly secured.
27
After replacing the line or section, pres-
surize the system and check for leaks.
Plastic lines
28 If replacement of a plastic line is
required, disassemble the applicable quick-
connect fittings as described above and
remove the line from the vehicle. The plastic
li nes used on these vehicles are not service-
able. If replacement is required, the affected
section of fuel line/quick-connect fittings
must be replaced as an assembly.
29 Install the new line onto the vehicle and
assemble the quick-connect fittings as appli-
cable (see above). Secure the line to the vehi-
cle as required. Warning: Plastic lines must
never be allowed to rub against other compo-
nents or each other. A minimum of 1/4-inch
clearance must be maintained to prevent
contact unless it is properly secured. Do not
route plastic fuel lines within four inches of
any part of the exhaust system or within ten
inches of the catalytic converter.
30
After replacing the line, pressurize the
system and check for leaks.
Rubber hoses
Warning: Fuel-injected vehicles use specially
constructed hoses. Only use hoses marked
EFM/EFI. Replace with only original equip-
ment hoses, or hoses that meet or exceed
original equipment standards. Others may
have a lower fatigue threshold.
31
Perform the fuel pressure relief proce-
dure (see Section 2).
32
Loosen the clamps securing the hose
and remove it from the vehicle.
33 Installation is the reverse of removal.
Warning: Do not route rubber fuel hoses
within four inches of any part of the exhaust
system or within ten inches of the catalytic
converter. Rubber hoses must never be
allowed to rub against other components or
each other. A minimum of 1/4-inch clearance
must be maintained to prevent contact with
other components unless it is properly
secured.
34
After replacing the hose, pressurize the
system and check for leaks.
5
Fuel tank - removal and
installation
Warning: Gasoline is extremely flammable,
so take extra precautions when you work on
any part of the fuel system (see the Warning
in Section 2).
Removal
Refer to illustrations 5.6 and 5.9
1
Remove the fuel tank filler cap to relieve
fuel tank pressure.
2
Perform the fuel pressure relief proce-
dure (see Section 2).
3
Disconnect the negative battery cable
from the ground stud on the left shock tower
(see Chapter 5, Section 1).
4
Working inside the trunk, fold back the
trunk mat near the base of the left shock
tower. Locate the fuel pump wiring har-
ness 4-pin connector and disconnect it from
the wiring harness (see illustration 2.3). Fol-
low the fuel pump wiring to the grommet at
the base of the rear seat. Push the grommet
through the floorpan and feed the wiring
and 4-pin connector through the hole.
5
Raise the vehicle and support it securely
on jackstands.
6
Position an approved gasoline container
under the fuel tank drain plug. If necessary,
use a funnel to prevent spilling fuel. Warning:
The fuel tank capacity is 16 gallons. Unless
the fuel tank is almost empty, be prepared to
collect a significant amount of fuel. Do not
leave the fuel tank draining operation unat-
tended. Be prepared to replace the drain plug
in case the fuel tank capacity exceeds the
container capacity. Remove the drain plug
(see illustration) and allow the fuel to exit the
fuel tank.
7
After the fuel has finished draining,
replace the drain plug and tighten it to the
torque listed in this Chapter's Specifications.
Warning: There will be approximately 1 to 2
gallons of fuel remaining inside the tank.
8
Loosen the clamp and detach the filler
neck hose from the fuel tank. Warning: There
may be fuel inside the filler neck and hose,
protect yourself accordingly.
9
Disconnect the quick-connect fuel line
fittings (see Section 4 if necessary) from the
fuel pump module (see illustration).
10
At the rear of the fuel tank, detach the
vapor hose from the rollover valve.
11
Support the fuel tank with a floor jack.
Chapter 4 Fuel and exhaust systems
4-7
FUEL LEVEL
SENSOR
7.6a Fuel pump module - component identification
7.6b When removing the fuel pump module from the fuel tank,
slightly angle the module to avoid damaging the fuel
level sending unit float arm
Place a piece of wood between the jack head
and the fuel tank to protect the tank.
12
Remove the fuel tank strap bolts and
straps.
13
On 1998 models, slightly lower the fuel
tank and detach the EVAP canister purge
li ne. Remove the hoses from the EVAP canis-
ter (see Chapter 6 if necessary) and discon-
nect the electrical connector from the Leak
Detection Pump (LDP). Note: Before discon-
necting any lines or hoses, clearly label the
hose and fitting so they can be reinstalled in
their proper locations.
14
Slightly lower the fuel tank and then
slide it forward to allow the filler neck to clear
the rear suspension crossmember. Remove
the tank from the vehicle.
Installation
15 Installation is the reverse of removal.
However, before installing the fuel tank, tie a
length of string or wire to the fuel pump mod-
ule wiring harness and route it through the
hole in the trunk floorpan. Once the fuel tank
is securely in position, pull the string to
access the wiring harness.
16
Tighten the fuel tank strap bolts to the
torque listed in this Chapter's Specifications.
6
Fuel tank cleaning and repair -
general information
Warning: Gasoline is extremely flammable,
so take extra precautions when you work on
any part of the fuel system. (See the Warning
in Section 2).
1
The fuel tank on these vehicles is made
of plastic and is not repairable.
2
If the fuel tank is removed from the vehi-
cle, do not place it in an area where sparks or
open flames could ignite the fuel vapors
escaping from the tank. Be especially careful
inside a garage where a natural gas-type
appliance is located, because the pilot light
could cause an explosion.
7
Fuel pump module - removal and
installation
Warning 1: Gasoline is extremely flammable,
so take extra precautions when you work on
any part of the fuel system (see the Warning
in Section 2).
Warning 2: The fuel reservoir in the fuel
pump module does not empty when the fuel
tank is drained. This fuel will drain out when
the fuel pump module is removed from the
fuel tank - protect yourself accordingly.
Caution: Be sure to change the fuel pump
module 0-ring seal whenever the assembly is
removed for service.
Note: The fuel pump module consists of the
following components; fuel pump, fuel pres-
sure regulator, fuel inlet strainer and fuel level
sending unit.
Removal
Refer to illustrations 7.6a and 7.6b
1
Perform the fuel pressure relief proce-
dure (see Section 2).
2
Disconnect the negative cable from the
remote battery terminal.
3
Remove the fuel tank from the vehicle
(see Section 5).
4
Clean the top of the fuel tank around the
fuel pump module to remove any dirt or
debris.
5
Using a large pair of pliers, remove the
fuel pump module ring nut. Caution: Do not
apply too much pressure on the ring nut dur-
ing removal or damage may result.
6
Remove the fuel pump module from the
tank (see illustrations). Angle the assembly
slightly to avoid damaging the fuel level send-
ing unit float arm. Remove and discard the 0-
ring seal.
7
The electric fuel pump is not service-
able. In the event of failure, the complete
assembly must be replaced. The only ser-
viceable parts on the fuel pump module are
the fuel inlet strainer, fuel pressure regulator
and the fuel level sending unit.
8
For service procedures on the fuel pres-
sure regulator and inlet strainer refer to Sec-
tion 14.
9
For service procedures on the fuel level
sending unit refer to Section 8.
Installation
10
Clean sealing area on the fuel tank.
Obtain the new fuel pump module 0-ring
seal. Lightly lubricate the 0-ring seal with
clean engine oil and install it on the fuel tank
opening.
11
Carefully insert the fuel pump module
into the fuel tank. Align the tab on the fuel
pump module with the notch in the fuel tank.
12
While holding the fuel pump module in
place, install the ring nut, tightening it
securely. Caution: Over-tightening the ring
nut may result in a leak.
13
The remaining installation steps are the
reverse of removal.
8
Fuel level sending unit - check
and replacement
Warning: Gasoline is extremely flammable,
so take extra precautions when you work on
any part of the fuel system (see the Warning
in Section 2).
Note: The fuel pump module consists of the
following components; fuel pump, fuel pres-
sure regulator, fuel inlet strainer and fuel level
sending unit.
Check
Refer to illustrations 8.3, 8.9 and 8.10
In-vehicle
1
Begin this procedure with the fuel tank
completely full.
2
Working inside the trunk, fold back the
trunk mat near the base of the left shock
tower. Locate the fuel pump wiring harness
4-pin connector and disconnect it from the
wiring harness (see illustration 2.3).
4
4-8
Chapter 4 Fuel and exhaust systems
1
Fuel level sending unit (ground)
2
Fuel pump (ground)
3
Fuel level sending unit (signal)
4
Fuel pump (positive feed)
FUEL PUMP
FUEL PUMP
GROUND
VOLTAGE SUPPLY
LEVEL SENSOR
GROUND
8.3 Fuel pump module electrical connector (fuel pump side)
terminal identification
8.9 Measuring the resistance of the fuel level sending unit with
the float arm in the FULL position
8.10 Measuring the resistance of the fuel level sending unit with
the float arm in the EMPTY position
8.13 Disconnect the electrical connector from the base of the fuel
pump module flange
3
Connect the probes of an ohmmeter to
the fuel level sending unit terminals of the fuel
pump module electrical connector and mea-
sure the resistance (see illustration). Com-
pare the measured resistance to the value
li sted in this Chapter's Specifications. If the
resistance is less than specified, replace the
fuel level sending unit.
4
Next, drive the vehicle until the fuel tank
is nearly empty or drain the fuel tank via the
drain plug into a container approved to hold
gasoline (see Section 5).
5
With the fuel tank empty, check the
resistance again (see illustration 8.3). Com-
pare the measured resistance to the value
li sted in this Chapter's Specifications. If the
resistance is out of tolerance, replace the fuel
level sending unit.
Removed from vehicle
6
A more thorough check of the fuel level
sending unit can be performed with the send-
ing unit removed from the vehicle.
7
Remove the fuel pump module (see
Section 7).
8
Connect the probes of an ohmmeter to
the fuel level sending unit terminals of the fuel
pump module electrical connector (see illus-
tration 8.3).
9
First, check the resistance of the send-
ing unit with the float arm in the FULL posi-
tion (see illustration). Compare the mea-
sured resistance to the value listed in this
Chapter's Specifications. If the resistance is
less than specified, replace the fuel level
sending unit.
10
Next, while observing the ohmmeter,
slowly lower the float arm to the EMPTY posi-
tion. The ohmmeter should register a smooth
change in resistance value from the FULL to
EMPTY position (see illustration). Compare
the measured resistance to the value listed in
this Chapter's Specifications. If the resis-
tance is out of tolerance or the ohmmeter
exhibited fluctuation during the transition
from FULL to EMPTY, replace the fuel level
sending unit.
Replacement
Refer to illustrations 8.13, 8.14, 8.15 and 8.17
11
Perform the fuel pressure relief proce-
dure (see Section 2).
12
Remove the fuel pump module (see
Section 7).
13
Disconnect the fuel level sensor/fuel
pump electrical connector from the base of
the fuel pump module flange (see illustra-
tion).
14
Use needle-nose pliers to remove the
blue locking wedge (see illustration).
15
Use a small screwdriver or needle-nose
pliers to lift the connector locking finger away
from the fuel level sending unit wire terminals
and then withdraw them from the module
8.14 Use needle-nose pliers and carefully
remove the blue locking wedge
Chapter 4 Fuel and exhaust systems
4-9
8.15 Use a small screwdriver, or needle-
nose pliers, and lift the locking fingers
away from the terminals, then carefully
remove the terminals from the connector
8.20 Terminal guide
for the fuel pump/fuel
level sending unit
(where it connects to
the base of the fuel
pump module flange)
electrical connector (see illustration).
16 If necessary, use factory tool No.
C-4334 or equivalent to remove the fuel level
sending unit terminals from the module con-
nector.
17
To remove the sending unit, insert a
screwdriver between the module fuel reservoir
and the top of the level sensor as shown and
pry the sensor down slightly (see illustration).
18
While guiding the sensor wires through
8.17 Using a screwdriver, pry the sensor
down slightly to disengage the
locking feature
the module fuel reservoir opening, slide the
sensor out of the channel.
Installation
Refer to illustrations 8.19 and 8.20
19
Place the wires into the guide groove on
the back side of the sending unit, route them
through the module fuel reservoir and then
slide the sensor up the channel until it snaps
into place (see illustration).
8.19 Place the wires into the groove on
the backside of the sending unit, then
while guiding the wires, slide the sending
unit up the channel until it snaps into
place - tug on it to ensure it's
locked into place
20 Install the wire terminals into the module
connector in their proper locations (see illus-
tration).
21
Install the blue locking wedge into the
module connector.
22
Verify the wire terminals are properly
installed in the module connector by gently
pulling on the wires.
23
Connect the fuel level sensor/fuel pump
electrical connector to the base of the fuel
pump module flange.
24
The remaining installation steps are the
reverse of removal.
9
Air cleaner assembly - removal
and installation
Removal
Refer
to illustrations 9.1a, 9.1b, 9.2, 9.4a and
9.4b
1
On the 2.0L four-cylinder engine and the
V6 engine, remove the air inlet resonator-to-
manifold bolts (see illustrations).
LEVEL SENSOR
GROUND
FUEL PUMP SUPPLY
LEVEL SENSOR
SIGNAL
4
MOUNTING BOLTS
9.1a Air inlet resonator-to-manifold bolts
(2.0L four-cylinder engine only)
9.1b Removing the air inlet resonator bolt (V6 engine)
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