Chrysler PT Cruiser. Manual — part 363
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
WARNING: The fuel system is under a constant pressure even with the
engine off. Before testing or servicing any fuel system hose,fitting or line,
the fuel system pressure must be released.
Remove the Fuel Pump Module and inspect the Fuel Inlet Strainer.
Is the Fuel Inlet Strainer plugged?
All
Yes
→ Replace the Fuel Pump Inlet Strainer.
Perform POWERTRAIN VERIFICATION TEST VER - 2 - NGC.
No
→ Replace the Fuel Pump Module.
Perform POWERTRAIN VERIFICATION TEST VER - 2 - NGC.
4
Fuel pressure gauge still installed.
NOTE: Fuel pressure specification is 400 KPa +/- 34 KPa (58 psi +/- 5 psi).
Ensure the fuel pressure is at maximum pressure.
Monitor the fuel pressure gauge for a minimum of 5 minutes.
NOTE: The pressure should not fall below 241 KPa (35 psi)
Does the fuel pressure gauge fall below the above specification?
All
Yes
→ Go To 5
No
→ Check the fuel for contaminants.
Perform POWERTRAIN VERIFICATION TEST VER - 2 - NGC.
5
NOTE: Before continuing visually and physically inspect the fuel delivery
system for external leaks or damage. Repair /replace as necessary.
Turn the ignition off.
WARNING: The fuel system is under a constant pressure even with the
engine off. Before testing or servicing any fuel system hose, fitting or line,
the fuel system pressure must be released.
Install special 5/16 fuel line adapter tool #6539.
Attach a fuel pressure test gauge to the T fitting on the tool #6539
Start the engine and allow the fuel system to reach maximum pressure.
Turn the ignition off.
NOTE: Fuel specification is 400 KPa +/- 34 KPa (58 psi +/- 5 psi).
Using special tool #C4390, Hose Clamp Pliers, slowly clamp off the rubber hose on
the Fuel Pressure adapter between the fuel pressure gauge and the engine.
Monitor the fuel pressure gauge for a minimum of 5 minutes.
NOTE: The pressure should not fall below 241 KPa (35 psi)
Does the fuel pressure gauge fall below the above specification?
All
Yes
→ Check the Fuel Delivery System between the fuel gauge and the
fuel pump module. Inspect the seal points and the fuel lines for
signs of fuel leakage. Repair/Replace as necessary. If OK, replace
the Fuel Pump Module.
Perform POWERTRAIN VERIFICATION TEST VER - 2 - NGC.
No
→ Check the Fuel Delivery System between the fuel gauge and the
fuel injectors. Inspect the seal points and the fuel lines for signs of
fuel leakage. Repair/Replace as necessary. If OK, replace the
leaking Fuel Injector(s).
Perform POWERTRAIN VERIFICATION TEST VER - 2 - NGC.
542
STARTING
*CHECKING HARD START (FUEL DELIVERY SYSTEM) —
Continued
Symptom:
*ENGINE CRANKS DOES NOT START - 1.6L
POSSIBLE CAUSES
FUEL PUMP RELAY
NO START PRE-TEST
OTHER POSSIBLE CAUSES FOR NO START
POWERTRAIN FUSES OPEN
FUEL PRESSURE OUT OF SPECS
RESTRICTED FUEL SUPPLY LINE
FUEL PUMP INLET STRAINER PLUGGED
FUEL PUMP MODULE
FUEL PUMP RELAY FUSED B+ CIRCUIT
FUEL PUMP RELAY OUTPUT CIRCUIT OPEN
FUEL PUMP GROUND CIRCUIT OPEN/HIGH RESISTANCE
FUEL PUMP MODULE
5 VOLT SUPPLY CIRCUIT
CKP SENSOR SIGNAL CIRCUIT SHORTED GROUND
CKP SENSOR SIGNAL CIRCUIT OPEN
CKP SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
CKP SENSOR SIGNAL SHORTED TO 5 VOLT SUPPLY CIRCUIT
SENSOR GROUND CIRCUIT OPEN
CRANKSHAFT POSITION SENSOR
PCM - CKP SENSOR SIGNAL
543
STARTING
TEST
ACTION
APPLICABILITY
1
Note: The following list of items must be checked before continuing with
any no start tests.
The battery must be fully charged and in good condition. An undercharged battery
can produce invalid test results.
If the battery is not fully charged, charge the battery and attempt to start the vehicle
by cranking the engine for 15 seconds, 3 consecutive times. This will allow any DTCs
to set that may have been erased due to a dead battery.
Make sure that all power and ground circuits to the PCM are ok.
Using the DRBIII
t, attempt to communicate with the PCM. If the DRBIIIt reports
a No Response condition from the PCM, refer to the symptom list in the Communi-
cation category for the proper diagnostic tests.
Using the DRBIII
t, read DTCs in the PCM. If any DTCs are present, refer to the
symptom list in the Driveability category for the proper diagnostic tests.
Using the DRBIII
t, attempt to communicate with the Instrument Cluster and the
SKIM module. If the DRBIII
t reports a No Response condition from either, refer to
the symptom list in the Communication category for the proper diagnostic tests.
Using the DRBIII
t, read DTCs in the SKIM module. If any DTCs are present, refer
to the symptom list in the Vehicle Theft/Security category for the proper diagnostic
tests.
If no DTCs are detected, use the DRBIII
t to perform a PCM Battery Disconnect.
Under Miscellaneous Functions, select Clear PCM (Batt Disconnect).
Crank the engine several times. Using the DRBIII
t, read DTCs in the PCM. If any
DTCs are set, refer to the symptom list in the Driveability category for the proper
diagnostic tests.
Were any problems found?
All
Yes
→ Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 1 - NGC.
No
→ Go To 2
2
Check for any open fuses in the PDC or Fuse Block that may be related to the No
Start condition.
Are any of the fuses open?
All
Yes
→ Using the wiring diagram/schematic as a guide, inspect the
wiring and connectors, repair as necessary. Replace the Fuse.
Perform POWERTRAIN VERIFICATION TEST VER - 1 - NGC.
No
→ Go To 3
3
Turn the ignition on.
With the DRBIII
t, actuate the ASD Fuel System test.
Note: It may be necessary to use a mechanics stethoscope in the next step.
Listen for fuel pump operation at the fuel tank.
Does the Fuel Pump operate?
All
Yes
→ Go To 4
No
→ Go To 18
Caution: Stop All Actuations.
544
STARTING
*ENGINE CRANKS DOES NOT START - 1.6L —
Continued
TEST
ACTION
APPLICABILITY
4
Turn the ignition off.
WARNING: The fuel system is under a constant pressure even with the
engine off. Before testing or servicing any fuel system hose, fitting or line,
the fuel system pressure must be released.
Install a fuel pressure gauge.
Turn the ignition on.
With the DRBIII
t, actuate the ASD Fuel System test and observe the fuel pressure
gauge.
NOTE: Fuel pressure specification is 400 kPa +/- 34 kPa (58 psi +/- 5 psi).
Choose a conclusion that best matches your fuel pressure reading.
All
Below Specification
Within Specification
Above Specification
Replace the fuel filter/fuel pressure regulator.
Perform POWERTRAIN VERIFICATION TEST VER - 1 - NGC.
Caution: Stop All Actuations.
5
Turn the ignition off.
WARNING: The fuel system is under a constant pressure even with the
engine off. Before testing or servicing any fuel system hose, fitting or line,
the fuel system pressure must be released.
Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module.
Install special 5/16 fuel line adapter tool #6539 between the disconnected fuel line
and the fuel pump module.
Attach a fuel pressure test gauge to the T fitting on the tool #6539
Turn the ignition on.
With the DRBIII
t, actuate the ASD Fuel System test and observe the fuel pressure
gauge.
NOTE: Fuel pressure specification is 400 KPa +/- 34 KPa (58 psi +/- 5 psi).
Is the fuel pressure within specification now?
All
Yes
→ Repair/replace fuel supply line as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 1 - NGC.
No
→ Go To 6
Caution: Stop All Actuations.
6
Turn the ignition off.
WARNING: The fuel system is under a constant pressure even with the
engine off. Before testing or servicing any fuel system hose,fitting or line,
the fuel system pressure must be released.
Remove the Fuel Pump Module and inspect the Fuel Inlet Strainer.
Is the Fuel Inlet Strainer plugged?
All
Yes
→ Replace the Fuel Pump Inlet Strainer.
Perform POWERTRAIN VERIFICATION TEST VER - 1 - NGC.
No
→ Replace the Fuel Pump Module.
Perform POWERTRAIN VERIFICATION TEST VER - 1 - NGC.
545
STARTING
*ENGINE CRANKS DOES NOT START - 1.6L —
Continued
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