Chrysler PT Cruiser. Manual — part 742
INSTALLATION
INSTALLATION - 2.0, 2.4L
(1) Install the fuel injectors to the fuel rail.
(2) Apply a light coating of clean engine oil to the
O-ring on the nozzle end of each injector.
(3) Insert fuel injector nozzles into openings in
intake manifold. Seat the injectors in place. Tighten
fuel rail bolts to 12 N·m (8 ft. lbs.) (Fig. 16).
(4) Attach electrical connectors to fuel injectors.
(5) Connect fuel supply tube to fuel rail. Refer to
Quick Connect Fittings in the Fuel Delivery section
(6) Install Intake Manifold, refer to the Engine
section.
(7) Install the engine cover or throttle control
shield if equipped.
(8) Install the negative battery cable.
(9) Install the air cleaner lid, connect the inlet air
temperature sensor and makeup air hose. Tighten air
inlet tube clamps to 3 N·m ±1 (25 in. lbs. ±5) torque.
INSTALLATION - 1.6L
(1) Apply a light coating of clean engine oil to the
upper O-ring.
(2) Install injector in cup on fuel rail.
(3) Install retaining clip.
(4) Apply a light coating of clean engine oil to the
O-ring on the nozzle end of each injector.
(5) Insert fuel injector nozzles into openings in
lower intake manifold (Fig. 19). Seat the injectors in
place. Tighten fuel rail mounting screws to 22.5 N·m
± 3 N·m (200±30 in. lbs.).
(6) Attach electrical connectors to fuel injectors
(Fig. 17), refer to the fuel injector connector section
for electrical connector installation.
(7) Connect fuel supply tube to fuel rail (Fig. 18).
Refer to Quick Connect Fittings in the Fuel Delivery
Section of this Group.
(8) Install the wiring harness to the fuel rail
brackets.
(9) Connect the negative battery cable.
(10) Use the DRB scan tool ASD Fuel System Test
to pressurize the fuel system. Check for leaks.
(11) Install air cleaner assembly cover.
INSTALLATION - 2.4L TURBO
(1) Apply a light coating of clean engine oil to the
upper O-ring.
(2) Install injector in cup on fuel rail.
(3) Install retaining clip.
(4) Install the fuel injectors to the fuel rail (Fig.
25).
(5) Apply a light coating of clean engine oil to the
O-ring on the nozzle end of each injector.
(6) Insert fuel injector nozzles into openings in
intake manifold. Seat the injectors in place.
(7) Install the 2 bolts to the fuel rail (Fig. 24).
Tighten fuel rail bolts to 22.5 ±3 N·m (200 ±30 in.
lbs.)
(8) Install the wiring harness to the fuel rail (Fig.
24).
(9) Connect and lock the electrical connectors to
the fuel injectors.
(10) Connect the fuel line to the fuel rail (Fig. 23).
Refer to Quick Connect Fittings in the Fuel Delivery
Section of this Group.
(11) Rotate the assembly back into place and
install the 2 bolts to the thermostat housing tighten
to 12.5 N·m (110 in. lbs.).
(12) Move the upper radiator house clamp back
into place (Fig. 19).
(13) Install the 2 small hoses to the thermostat
housing (Fig. 20).
(14) Fill the Coolant system, refer to the Cooling
section for more information.
(15) Install the intake manifold, refer to the
Engine section.
(16) Install the 2 bolts to the rear of the intake
manifold (Fig. 17) tighten to 28 N·m (250 in. lbs.).
(17) Install the 5 bolts to the front of the intake
manifold and tighten to 28 N·m (250 in. lbs.).
(18) Install the vacuum lines to the rear of the
intake manifold (Fig. 17).
(19) Connect and lock the MAP sensor electrical
connector (Fig. 16).
(20) Install the cables to the throttle body bracket.
(21) Install the throttle and speed control cables to
the throttle body.
(22) Install the throttle control shield (Fig. 15).
(23) Connect and lock the electrical connections at
the throttle body (Fig. 14).
(24) Connect the purge hose to the throttle body
(Fig. 14).
(25) Connect the throttle body inlet hose to the
throttle body (Fig. 14) and tighten clamps to 3 N·m
±1 (25 in. lbs. ±5) torque.
(26) Connect the negative battery cable.
(27) Use the DRB scan tool ASD Fuel System Test
to pressurize the fuel system. Check for leaks.
FUEL PUMP RELAY
DESCRIPTION
The fuel pump relay is located in the PDC. The
inside top of the PDC cover has a label showing relay
and fuse location.
OPERATION
The fuel pump relay supplies battery voltage to the
fuel pump. A buss bar in the Power Distribution Cen-
ter (PDC) supplies voltage to the solenoid side and
14 - 36
FUEL INJECTION
PT
FUEL INJECTOR (Continued)
contact side of the relay. The fuel pump relay power
circuit contains a fuse between the buss bar in the
PDC and the relay. The fuse is located in the PDC.
Refer to the Wiring Diagrams for circuit information.
The PCM controls the fuel pump relay by switch-
ing the ground path for the solenoid side of the relay
on and off. The PCM turns the ground path off when
the ignition switch is in the Off position. When the
ignition switch is in the On position, the PCM ener-
gizes the fuel pump. If the crankshaft position sensor
does not detect engine rotation, the PCM de-ener-
gizes the relay after approximately one second.
IDLE AIR CONTROL MOTOR
DESCRIPTION
The Idle Air Control (IAC) motor is mounted on the
throttle body. The PCM operates the idle air control
motor (Fig. 32) or (Fig. 33).
OPERATION
The PCM adjusts engine idle speed through the
idle air control valve to compensate for engine load,
coolant temperature or barometric pressure changes.
The throttle body has an air bypass passage that
provides air for the engine during closed throttle idle.
The idle air control valve regulates air flow through
the bypass passage.
The PCM controls engine idle speed by adjusting
the position of the idle air control valve. The adjust-
ments are based on inputs the PCM receives. The
inputs are from the throttle position sensor, crank-
shaft position sensor, coolant temperature sensor,
MAP sensor, vehicle speed sensor and various switch
operations (brake, park/neutral, air conditioning).
When engine rpm is above idle speed, the IAC is
used for the following functions:
• Off-idle dashpot
• Deceleration air flow control
• A/C compressor load control (also opens the pas-
sage slightly before the compressor is engaged so
that the engine rpm does not dip down when the
compressor engages)
Target Idle
Target idle is determined by the following inputs:
• Gear position
• ECT Sensor
• Battery voltage
• Ambient/Battery Temperature Sensor
• VSS
• TPS
• MAP Sensor
REMOVAL
When servicing throttle body components, always
reassemble components with new O-rings and seals
where applicable. Never use lubricants on O-rings or
seals, damage may result. If assembly of component
is difficult, use water to aid assembly.
(1) Disconnect negative cable from battery.
(2) Remove electrical connector from idle air con-
trol motor.
(3) Remove idle air control motor mounting screws.
Fig. 32 Idle Air Control Motor—2.4L
1 - IAC
2 - PCM
3 - TPS
Fig. 33 THROTTLE BODY CONNECTIONS - 2.4L
TURBO
1 - Purge Hose
2 - Electrical Connections
3 - Inlet Hose
PT
FUEL INJECTION
14 - 37
FUEL PUMP RELAY (Continued)
(4) Remove motor from throttle body. Ensure the
O-rings is removed with the motor.
INSTALLATION
When servicing throttle body components, always
reassemble components with new O-rings and seals
where applicable. Never use lubricants on O-rings or
seals, damage may result. If assembly of component
is difficult, a light coat of engine oil may be
applied to the O-RINGS ONLY (Fig. 34) to aid
assembly.
(1) The new idle air control motor has a new
O-ring installed on it.
(2) Carefully place idle air control motor into
throttle body.
(3) Install mounting screw. Tighten screw to 7 N·m
(62 in. lbs.) torque.
(4) Connect electrical connector to idle air control
motor.
(5) Connect negative cable to battery.
INLET AIR TEMPERATURE
SENSOR
DESCRIPTION
The IAT Sensor is a Negative Temperature Coeffi-
cient (NTC) Sensor that provides information to the
PCM regarding the temperature of the air entering
the intake manifold (Fig. 35).
REMOVAL
The sensor is located in the clean air duct.
(1) Unlatch or unbolt the air cleaner lid.
(2) Lift air cleaner lid and reposition.
(3) Disconnect the negative battery cable.
(4) Disconnect electrical connector from the sensor
(Fig. 35).
(5) Remove the sensors.
INSTALLATION
The sensors is in the air inlet tube.
(1) Install sensor.
(2) Attach electrical connector to sensor.
(3) Connect the negative battery cable.
(4) Install the air cleaner lid..
MAP SENSOR
DESCRIPTION
The MAP sensor mounts to the intake manifold
(Fig. 36).
Fig. 34 O-RINGS
1 - O-rings
Fig. 35 Inlet Air Temperature Sensor
1 - INLET AIR TEMPERATURE SENSOR
Fig. 36 MAP Sensor
1 - MAP SENSOR
14 - 38
FUEL INJECTION
PT
IDLE AIR CONTROL MOTOR (Continued)
OPERATION
The MAP serves as a PCM input, using a silicon
based sensing unit, to provide data on the manifold
vacuum that draws the air/fuel mixture into the com-
bustion chamber. The PCM requires this information
to determine injector pulse width and spark advance.
When MAP equals Barometric pressure, the pulse
width will be at maximum.
Also like the cam and crank sensors, a 5 volt ref-
erence is supplied from the PCM and returns a volt-
age
signal
to
the
PCM
that
reflects
manifold
pressure. The zero pressure reading is 0.5V and full
scale is 4.5V. For a pressure swing of 0 — 15 psi the
voltage changes 4.0V. The sensor is supplied a regu-
lated 4.8 to 5.1 volts to operate the sensor. Like the
cam and crank sensors ground is provided through
the sensor return circuit.
The MAP sensor input is the number one contrib-
utor to pulse width. The most important function of
the MAP sensor is to determine barometric pressure.
The PCM needs to know if the vehicle is at sea level
or is it in Denver at 5000 feet above sea level,
because the air density changes with altitude. It will
also help to correct for varying weather conditions. If
a hurricane was coming through the pressure would
be very, very low or there could be a real fair
weather, high pressure area. This is important
because as air pressure changes the barometric pres-
sure changes. Barometric pressure and altitude have
a direct inverse correlation, as altitude goes up baro-
metric goes down. The first thing that happens as
the key is rolled on, before reaching the crank posi-
tion, the PCM powers up, comes around and looks at
the MAP voltage, and based upon the voltage it sees,
it knows the current barometric pressure relative to
altitude. Once the engine starts, the PCM looks at
the voltage again, continuously every 12 milliseconds,
and compares the current voltage to what it was at
key on. The difference between current and what it
was at key on is manifold vacuum.
During key On (engine not running) the sensor
reads (updates) barometric pressure. A normal range
can be obtained by monitoring known good sensor in
you work area.
As the altitude increases the air becomes thinner
(less oxygen). If a vehicle is started and driven to a
very different altitude than where it was at key On
the barometric pressure needs to be updated. Any
time the PCM sees Wide Open throttle, based upon
TPS angle and RPM it will update barometric pres-
sure in the MAP memory cell. With periodic updates,
the PCM can make its calculations more effectively.
The PCM uses the MAP sensor to aid in calculat-
ing the following:
• Barometric pressure
• Engine load
• Manifold pressure
• Injector pulse-width
• Spark-advance programs
• Shift-point strategies (F4AC1 transmissions
only, via the PCI bus)
• Idle speed
• Decel fuel shutoff
The PCM recognizes a decrease in manifold pres-
sure by monitoring a decrease in voltage from the
reading stored in the barometric pressure memory
cell. The MAP sensor is a linear sensor; as pressure
changes, voltage changes proportionately. The range
of voltage output from the sensor is usually between
4.6 volts at sea level to as low as 0.3 volts at 26 in. of
Hg. Barometric pressure is the pressure exerted by
the atmosphere upon an object. At sea level on a
standard day, no storm, barometric pressure is 29.92
in Hg. For every 100 feet of altitude barometric pres-
sure drops .10 in. Hg. If a storm goes through it can
either add, high pressure, or decrease, low pressure,
from what should be present for that altitude. You
should make a habit of knowing what the average
pressure and corresponding barometric pressure is
for your area.
REMOVAL
REMOVAL - 2.0, 2.4, 2.4L TURBO
The MAP sensor attaches to the intake manifold
plenum (Fig. 37).
(1) Remove the air cleaner lid and makeup air
hose.
(2) Remove the negative battery cable.
(3) Disconnect the electrical connector from the
MAP sensor.
(4) Remove sensor mounting screws.
(5) Remove sensor.
REMOVAL - 1.6L
(1) Remove the air cleaner cover.
(2) Disconnect the negative battery cable.
(3) Disconnect the electrical connector from the
MAP sensor (Fig. 38).
(4) Remove the screws from the MAP sensor.
(5) Remove the MAP sensor.
INSTALLATION
INSTALLATION - 2.0, 2.4, 2.4L Turbo
The MAP sensor attaches to the intake manifold
plenum (Fig. 37).
(1) Insert sensor into intake manifold while mak-
ing sure not to damage O-ring seal.
(2) Tighten mounting screws to 2 N·m (20 in. lbs)
torque for plastic manifold.
PT
FUEL INJECTION
14 - 39
MAP SENSOR (Continued)
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