Chrysler PT Cruiser. Manual — part 736
(18) Disconnect the fuel line from the fuel rail
(Fig. 23). Refer to the Quick-Connect Fittings in this
section.
(19) Unlock and disconnect the electrical connec-
tors from the fuel injectors.
(20) Remove the wiring harness from the fuel rail
(Fig. 24).
(21) Remove the 2 bolts from the fuel rail (Fig. 24).
(22) Remove the fuel rail and injectors from the
intake manifold (Fig. 25).
REMOVAL - 1.6L
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE
SERVICING
THE
VEHICLE.
THIS
MAY
RESULT IN PERSONAL INJURY OR DEATH.
(1) Remove air cleaner assembly cover.
(2) Disconnect the negative battery cable.
(3) Disconnect the electrical connectors from the
fuel injectors (Fig. 26)
(4) Remove the wiring harness from the fuel rail
brackets.
Fig. 22 HOSE AND HOUSING ROTATED - 2.4L
TURBO
Fig. 23 FUEL LINE CONNECTION - 2.4L TURBO
Fig. 24 FUEL RAIL - 2.4L TURBO
Fig. 25 FUEL RAIL & INJECTORS - 2.4L TURBO
14 - 12
FUEL DELIVERY
PT
FUEL RAIL (Continued)
(5) Remove the fuel line from the fuel rail (Fig.
27).
(6) Remove the 2 bolts to the fuel rail at the lower
manifold.
(7) Remove the fuel rail (Fig. 28)
(8) Remove the fuel injectors from the rail.
INSTALLATION
INSTALLATION
(1) Install 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 22.5 ±3 N·m (200 ±30 in. lbs.) (Fig.
13).
(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 - 2.4L TURBO
(1) Install the fuel injectors to the fuel rail (Fig.
25).
(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.
(4) Install the 2 bolts to the fuel rail (Fig. 24).
Tighten fuel rail bolts to 22.5 ±3 N·m (200 ±30 in.
lbs.)
(5) Install the wiring harness to the fuel rail (Fig.
24).
(6) Connect and lock the electrical connectors to
the fuel injectors.
(7) Connect the fuel line to the fuel rail (Fig. 23).
Refer to Quick Connect Fittings in the Fuel Delivery
Section of this Group.
Fig. 26 INJECTOR CONNECTOR AND WIRING
HARNESS
1 - FUEL INJECTOR ELECTRICAL CONNECTOR
2 - WIRING HARNESS
Fig. 27 FUEL LINE
Fig. 28 FUEL RAIL AND FUEL INJECTOR
PT
FUEL DELIVERY
14 - 13
FUEL RAIL (Continued)
(8) Rotate the assembly back into place and install
the 2 bolts to the thermostat housing tighten to 12.5
N·m (110 in. lbs.).
(9) Move the upper radiator house clamp back into
place (Fig. 19).
(10) Install the 2 small hoses to the thermostat
housing (Fig. 20).
(11) Fill the Coolant system, refer to the Cooling
section for more information.
(12) Install the intake manifold, refer to the
Engine section.
(13) Install the 2 bolts to the rear of the intake
manifold (Fig. 17) tighten to 28 N·m (250 in. lbs.).
(14) Install the 5 bolts to the front of the intake
manifold and tighten to 28 N·m (250 in. lbs.).
(15) Install the vacuum lines to the rear of the
intake manifold (Fig. 17).
(16) Connect and lock the MAP sensor electrical
connector (Fig. 16).
(17) Install the cables to the throttle body bracket.
(18) Install the throttle and speed control cables to
the throttle body.
(19) Install the throttle control shield (Fig. 15).
(20) Connect and lock the electrical connections at
the throttle body (Fig. 14).
(21) Connect the purge hose to the throttle body
(Fig. 14).
(22) 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.
(23) Connect the negative battery cable.
(24) Use the DRB scan tool ASD Fuel System Test
to pressurize the fuel system. Check for leaks.
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. 28). 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. 26), refer to the fuel injector connector section
for electrical connector installation.
(7) Connect fuel supply tube to fuel rail (Fig. 27).
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.
FUEL TANK
DESCRIPTION
The fuel tank is constructed of a plastic material.
Its main functions are for fuel storage and for place-
ment of the fuel pump module. The tank is made
from High density Polyethylene (HDPE) material.If
equipped with ORVR (Onboard Refueling Vapor
Recovery) it has been added to the fuel tank to con-
trol refueling vapor emissions.
OPERATION
All models pass a full 360 degree rollover test
without fuel leakage. To accomplish this, fuel and
vapor flow controls are required for all fuel tank con-
nections.
All models are equipped with either one or two
check valves mounted into the top of the fuel tank (or
pump module).
An evaporation control system is connected to the
check valve(s)/control valve(Refer to 25 - EMIS-
SIONS
CONTROL/EVAPORATIVE
EMISSIONS/
ORVR - OPERATION) to reduce emissions of fuel
vapors into the atmosphere, when the tank is vented
due to vapor expansion in the tank. When fuel evap-
orates from the fuel tank, vapors pass through vent
hoses or tubes to a charcoal canister where they are
temporarily held. When the engine is running, the
vapors are drawn into the intake manifold. In addi-
tion, fuel vapors produced during vehicle refueling
are allowed to pass through the vent hoses/tubes to
the charcoal canister(s) for temporary storage (prior
to being drawn into the intake manifold). All models
are equipped with a self-diagnosing system using a
Leak Detection Pump (LDP) or Natural Vacuum
Leak Detection (NVLD). Refer to the Emission Con-
trol System for additional information.
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.
REMOVAL
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE
SERVICING
THE
VEHICLE.
THIS
MAY
RESULT IN PERSONAL INJURY OR DEATH.
14 - 14
FUEL DELIVERY
PT
FUEL RAIL (Continued)
(1) Release fuel system pressure. Refer to Fuel
Pressure Release Procedure in this section.
(2) Remove the air cleaner lid, disconnect the inlet
air temperature sensor and makeup air hose.
(3) Remove the negative battery cable.
(4) Remove fuel cap slowly to release tank pres-
sure.
(5) With vehicle on a hoist, drain fuel from tank.
Drain fuel tank refer to Draining the Fuel Tank in
this section.
(6) Raise and support the vehicle.
CAUTION: There may be fuel in the fill tube.
Remove hose carefully to reduce fuel splash.
(7) Disconnect fuel tank from rubber fill hose.
NOTE: wrap shop towels around hoses to catch any
gasoline spillage.
(8) Remove bolts from the fuel tank straps (Fig.
29).
(9) Lower fuel tank and remove the EVAP line and
recirculation line.
(10) Remove vacuum line from LDP.
(11) Disconnect fuel line, it is in the front of the
fuel tank. This is a quick connect fittings (Fig. 30).
(12) Unlock the electrical connector then discon-
nect the electrical connector (Fig. 31)
(13) Remove hoses from EVAP canister.
(14) Remove fuel tank from vehicle.
INSTALLATION
(1) Position fuel tank on transmission jack.
(2) Raise fuel tank into position.
(3) Connect vacuum line to LDP.
(4) Install EVAP line and recirculation line.
(5) Connect electrical connector (Fig. 31) and lock
the connector.
(6) Connect the fuel line (Fig. 30). Refer to Quick
Connect Fittings in this section.
(7) Connect fuel fill tube to tank inlet. Tighten
hose clamp to 3.5 N·m (31 in. lbs.) torque.
(8) Position fuel tank straps. Tighten fuel tank
strap bolts to 23 N·m (250 in. lbs.) torque (Fig. 29).
Remove transmission jack. Ensure straps are not
twisted or bent.
(9) Lower vehicle.
Fig. 29 Fuel Tank Straps
Fig. 30 Fuel Line
1 - FUEL LINE
2 - FUEL TANK
Fig. 31 Electrical Connector
PT
FUEL DELIVERY
14 - 15
FUEL TANK (Continued)
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