Chrysler PT Cruiser. Manual — part 734
FUEL FILTER
DESCRIPTION
The fuel filter mounts inside the fuel pump module
and is a non-serviceable part.
FUEL LEVEL SENDING UNIT /
SENSOR
DESCRIPTION
The fuel gauge level sending unit is attached to the
side of fuel pump module. The level sensor is a vari-
able resistor.
OPERATION
Its resistance changes with the amount of fuel in
the tank. The float arm attached to the sensor moves
as the fuel level changes.
The fuel level input is used as an input for OBD II.
If the fuel level is below 15% or above 85% of total
tank capacity several monitors are disabled. There
are diagnostics for the level circuit open and shorted.
REMOVAL
(1) Remove fuel pump module. Refer to Fuel Pump
Module in this section.
(2) Depress retaining tab and remove the fuel
pump/level sensor connector from the BOTTOM of
the fuel pump module electrical connector (Fig. 1).
NOTE: The pump module harness on TOP of flange
is not serviceable or removable.
(3) Remove the wedge lock from the electrical con-
nector (Fig. 2).
Fuel Line Adapter 1/4
O2S (Oxygen Sensor) Remover/Installer—C-4907
O2S (Oxygen Sensor) Remover/Installer - 8439
Fig. 1 Fuel Pump/Level Sensor Electrical Connector
1 - ELECTRICAL CONNECTOR
Fig. 2 Wedge Lock
14 - 4
FUEL DELIVERY
PT
FUEL DELIVERY (Continued)
(4) Using Special Tool C-4334 terminal remover or
equivalent, remove terminals from level sensor con-
nector (Fig. 3).
(5) Depress the tab and slide the sensor toward
the bottom of the fuel pump module (Fig. 4).
(6) Slide level sensor out of channel in module.
INSTALLATION
(1) Wrap wires into groove in back of level sensor
(Fig. 5).
(2) While feeding wires into guide grooves, slide
level sensor up into channel until it snaps into place
(Fig. 4). Ensure tab at bottom of sensor locks in
place.
(3) Install level sensor wires in connector. Push
the wires up through the connector and then pull
them down until they lock in place. Ensure signal
and ground wires are installed in the correct position
refer to the Wiring section.
(4) Install locking wedge on connector (Fig. 2).
(5) Push connector up into bottom of fuel pump
module electrical connector (Fig. 1).
(6) Install fuel pump module. Refer to Fuel Pump
Module in this section.
FUEL LINES
DESCRIPTION - FUEL LINES/HOSES AND
CLAMPS
Also refer to Quick-Connect Fittings.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRES-
SURE MUST BE RELEASED. REFER TO THE FUEL
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP. THIS MAY RESULT IN PERSONAL
INJURY OR DEATH.
The lines/tubes/hoses used on fuel injected vehicles
are of a special construction. This is due to the
higher fuel pressures and the possibility of contami-
nated fuel in this system. If it is necessary to replace
these lines/tubes/hoses, only those marked EFM/EFI
may be used.
If equipped: The hose clamps used to secure rub-
ber hoses on fuel injected vehicles are of a special
rolled edge construction. This construction is used to
prevent the edge of the clamp from cutting into the
Fig. 3 Terminal Removal Tool-Tyipcal
1 - TERMINAL REMOVAL TOOL
2 - FUEL LEVEL SENSOR CONNECTOR
Fig. 4 Level Sensor
1 - FUEL LEVER SENSOR
Fig. 5 Groove in Back Side of Level Sensor
1 - WIRING GROOVE
PT
FUEL DELIVERY
14 - 5
FUEL LEVEL SENDING UNIT / SENSOR (Continued)
hose. Only these rolled edge type clamps may be
used in this system. All other types of clamps may
cut into the hoses and cause high-pressure fuel leaks.
Use new original equipment type hose clamps.
STANDARD PROCEDURE - HOSES AND CLAMP
Inspect all hose connections (clamps and quick con-
nect fittings) for completeness and leaks. Replace
cracked, scuffed, or swelled hoses. Replace hoses that
rub against other vehicle components or show sign of
wear.
Fuel injected vehicles use specially constructed
hoses. When replacing hoses, only use hoses marked
EFM/EFI.
When installing hoses, ensure that they are routed
away from contact with other vehicle components
that could rub against them and cause failure. Avoid
contact with clamps or other components that cause
abrasions or scuffing. Ensure that rubber hoses are
properly routed and avoid heat sources.
The hose clamps have rolled edges to prevent the
clamp from cutting into the hose. Only use clamps
that are original equipment or equivalent. Other
types of clamps may cut into the hoses and cause
high pressure fuel leaks. Tighten hose clamps to 1
N·m (9 in. lbs.) torque.
Inspect all hose connections such as clamps, cou-
plings and fittings to make sure they are secure and
leaks are not present. The component should be
replaced immediately if there is any evidence of deg-
radation that could result in failure.
Never attempt to repair a plastic fuel line/tube.
Replace as necessary.
Avoid contact of any fuel tubes/hoses with other
vehicle components that could cause abrasions or
scuffing. Be sure that the plastic fuel lines/tubes are
properly routed to prevent pinching and to avoid heat
sources.
FUEL PRESSURE REGULATOR
DESCRIPTION
The fuel pressure regulator contains a diaphragm,
calibrated spring and a fuel return valve. The regu-
lator is mounted in the fuel pump module (Fig. 6).
OPERATION
The fuel system uses a nonadjustable pressure reg-
ulator
that
maintains
fuel
system
pressure
at
approximately 400 ±34 kPa (58 ±5 psi). The fuel
pressure regulator contains a diaphragm, calibrated
spring and a fuel return valve. The spring pushes
down on the diaphragm and closes off the fuel return
port. System fuel pressure reflects the amount of fuel
pressure required to open the return port.
The pressure regulator is a mechanical device that
is NOT controlled by the PCM or engine vacuum.
REMOVAL
The fuel pressure regulator is part of the fuel
pump module (Fig. 7). Remove the fuel pump module
from the fuel tank to access the fuel pressure regula-
tor. Refer to the Fuel Pump Module removal in this
section.
WARNING: FUEL SYSTEM PRESSURE MUST BE
RELEASED BEFORE SERVICING ANY FUEL SYS-
TEM COMPONENT. PERFORM THE FUEL SYSTEM
PRESSURE
RELEASE
PROCEDURE.
THIS
MAY
RESULT IN PERSONAL INJURY OR DEATH.
Fig. 6 Fuel Pressure Regulator
1 - FUEL PRESSURE REGULATOR
Fig. 7 Fuel Pressure Regulator Retainer
1 - FUEL PRESSURE REGULATOR
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FUEL DELIVERY
PT
FUEL LINES (Continued)
(1) Spread tangs on pressure regulator retainer
(Fig. 7).
(2) Pry fuel pressure regulator out of housing.
(3) Ensure that the O-ring was removed with reg-
ulator (Fig. 8).
INSTALLATION
The fuel pressure regulator is part of the fuel
pump module (Fig. 7). Remove the fuel pump module
from the fuel tank to access the fuel pressure regula-
tor. Refer to the Fuel Pump Module removal in this
section.
(1) Lightly lubricate the O-ring with clean engine
oil and place them into opening in pump module.
(2) Push regulator into opening in pump module.
(3) Push regulator retainer over tabs on housing.
(4) Install Fuel Pump Module, refer to the Fuel
Pump Module installation in this section.
FUEL PUMP
DESCRIPTION
The electric fuel pump is located in and is part of
the fuel pump module. It is a positive displacement,
gerotor type, immersible pump with a permanent
magnet electric motor. The fuel pump module is sus-
pended in fuel in the fuel tank.
OPERATION
The pump draws fuel through a strainer and
pushes it through the motor to the outlet. The pump
contains a check valve. The valve, in the pump out-
let, maintains pump pressure during engine off con-
ditions, for a short while. It is normal for fuel
pressure to drop to zero after cooldown. The fuel
pump relay provides voltage to the fuel pump. The
fuel pump has a maximum deadheaded pressure out-
put of approximately 880 kPa (130 psi). The regula-
tor adjusts fuel system pressure to approximately
400 kpa ±34 kpa (58 psi ± 5 psi).
NOTE: Checkvalve maintains volume of fuel in the
rail and lines, not pressure.
FUEL PUMP MODULE
DESCRIPTION
The fuel pump module is installed in the top of the
fuel tank (Fig. 9).
The fuel pump module contains the following:
• Electric fuel pump
• Fuel pump reservoir
• Inlet strainer
• Fuel pressure regulator
• Fuel gauge sending unit
• Fuel supply line connection
• Fuel Filter
The fuel level sensor and the pressure regula-
tor are the only serviceable items. If the fuel
pump or electrical wiring harness requires ser-
vice, replace the fuel pump module.
OPERATION
The pump draws fuel through a strainer and
pushes it through the motor to the outlet. The pump
contains one check valve. The check valve, in the
pump outlet, maintains pump pressure during engine
off conditions. The fuel pump relay provides voltage
to the fuel pump.
Fig. 8 Fuel Pressure Regulator Retainer
1 - FUEL PRESSURE REGULATOR
Fig. 9 Fuel Pump Module
PT
FUEL DELIVERY
14 - 7
FUEL PRESSURE REGULATOR (Continued)
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