Chrysler PT Cruiser. Manual — part 221
If an injector is replaced, it is then necessary to
assign the classification number to the corresponding
cylinder with the DRBIII
t in the control module.
INJECTOR CLASSIFICATION PROCEDURE
(1) Turn ignition switch “ON”.
(2) Using a DRB III
t and select ENGINE then
MISCELLANEOUS.
(3) Select LEARN INJECTORS.
(4) Using the up and down arrows, scroll to the
appropriate injector.
(5) Using the right and left arrows, set injector to
proper classification.
(6) Once injectors are classified, cycle ignition to
complete.
REMOVAL
WARNING: HIGH-PRESSURE FUEL LINES DELIVER
FUEL UNDER EXTREME PRESSURE FROM THE
INJECTION
PUMP
TO
THE
INJECTORS.
THIS
MAYBE AS HIGH AS 1600BAR (23,200PSI). USE
EXTREME CAUTION WHEN INSPECTING FOR HIGH-
PRESSURE
FUEL
LEAKS.
FUEL
UNDER
THIS
AMOUNT OF PRESSURE CAN PENETRATE SKIN
CAUSING PERSONAL INJURY OR DEATH. INSPECT
HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF
CARDBOARD. WEAR SAFETY GOGGLES AND ADE-
QUATE PROTECTIVE CLOTHING WHEN SERVICING
FUEL SYSTEM.
CAUTION: PAY CLOSE ATTENTION TO THE FOL-
LOWING POINTS WHEN REMOVING FUEL INJEC-
TORS:
•
Injectors MUST be removed only using the spe-
cial tools provided for this purpose.
•
Injectors MUST NOT be disassembled.
•
Before cleaning injector recesses, seal all
injector holes in the injector recesses with a pin.
•
Clean all injector recesses in the cylinder head
with a non-woven cloth and then a cylinder brush.
•
Carefully clean sealing surfaces of injector
recesses with the round brush. DO NOT us a power
brush.
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE
COVER - REMOVAL).
(3) Disconnect fuel injector supply line from injec-
tor and fuel rail and remove from engine (Fig. 9)
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
FUEL LINES - REMOVAL).
NOTE: If injectors are tight and cannot be removed
by hand, remove with special tools #8937 slide
hammer and #8938 extraction claw (Fig. 10).
(4) Remove fuel injector retaining bolt and tension-
ing claw (Fig. 10).
(5) Remove fuel injector from cylinder head (Fig.
10).
Fig. 8 INJECTOR CLASSIFICATION MARKINGS
Fig. 9 FUEL INJECTOR AND GLOW PLUG
LOCATIONS
1 - FUEL INJECTORS
2 - GLOW PLUGS
3 - FUEL RAIL
4 - HIGH PRESSURE FUEL LINE
14 - 22
FUEL INJECTION
PT
FUEL INJECTOR (Continued)
INSTALLATION
WARNING: HIGH-PRESSURE FUEL LINES DELIVER
FUEL UNDER EXTREME PRESSURE FROM THE
INJECTION
PUMP
TO
THE
INJECTORS.
THIS
MAYBE AS HIGH AS 1600BAR (23,200PSI). USE
EXTREME CAUTION WHEN INSPECTING FOR HIGH-
PRESSURE
FUEL
LEAKS.
FUEL
UNDER
THIS
AMOUNT OF PRESSURE CAN PENETRATE SKIN
CAUSING PERSONAL INJURY OR DEATH. INSPECT
HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF
CARDBOARD. WEAR SAFETY GOGGLES AND ADE-
QUATE PROTECTIVE CLOTHING WHEN SERVICING
FUEL SYSTEM.
Fig. 10 FUEL INJECTOR REMOVAL/INSTALLATION - TYPICAL
1 - INJECTOR DRAIN TUBES
2 - RETAINING CLIP
3 - INJECTOR HIGH PRESSURE LINE
4 - INJECTOR SEAL
5 - FUEL INJECTOR
6 - TENSIONING CLAW
7 - SPECIAL TOOLS #8938 AND #8937
PT
FUEL INJECTION
14 - 23
FUEL INJECTOR (Continued)
CAUTION: PAY CLOSE ATTENTION TO THE FOL-
LOWING POINTS WHEN INSTALLING FUEL INJEC-
TORS.
•
Blow out injector recesses, clean again with
non-woven cloth and then cover over. Fiber resi-
dues from non-woven cloth ARE NOT permissible.
•
Carefully carry out a visual inspection of the
sealing surfaces of the injector recesses.
•
The length of the round brush can be adjusted
and should be approximately 3mm for cleaning the
seal seat. Optimal cleaning is achieved only if a
brush with a flat surface is used. If necessary the
surface of the brush can be ground flat on a grind-
ing stone.
•
ALWAYS replace the seals which seal off the
injectors at the cylinder head to the combustion
chamber. It is important that no grease gets onto
the seal. Any impurities on the seal, on the sealing
surfaces at the injector and cylinder head as a
result of combustion residue or similar are abso-
lutely impermissible.
•
The screws attaching the injectors must always
be replaced. The screws must screw in easily, if
not, clean the threaded whole with an appropriate
thread tap.
•
The tip of the injector nozzle MUST NOT be
cleaned with a wire brush. Use a non-woven cloth.
•
Clean entire injector with a non-woven cloth.
•
Fiber residues from a non-woven cloth are not
permissible.
•
Apply a thin film of special grease to the injec-
tor stems.
•
Remove the pin in the nozzle holes with the
extension.
(1) Clean injectors and recesses (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - STANDARD PROCEDURE).
(2) Coat injector body with anti seize lubricant and
install injectors with new seals (Fig. 10).
(3) Install tensioning claw with new fastener (Fig.
10). Torque in two stages, 7N·m (62 lbs.in.) then 90°.
NOTE:
If
drain
tube
locking
clips
have
been
removed from injectors, the clips must be replaced.
(4) Connect fuel drain tubes at injectors (Fig. 10).
(5) Install high pressure fuel lines from rail to
injectors (Fig. 10) (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/FUEL LINES - INSTALLATION).
(6) Connect injector electrical connectors.
(7) Connect negative battery cable.
WARNING: HIGH-PRESSURE FUEL LINES DELIVER
FUEL UNDER EXTREME PRESSURE FROM THE
INJECTION
PUMP
TO
THE
INJECTORS.
THIS
MAYBE AS HIGH AS 1600BAR (23,200PSI). USE
EXTREME CAUTION WHEN INSPECTING FOR HIGH-
PRESSURE
FUEL
LEAKS.
FUEL
UNDER
THIS
AMOUNT OF PRESSURE CAN PENETRATE SKIN
CAUSING PERSONAL INJURY OR DEATH. INSPECT
HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF
CARDBOARD. WEAR SAFETY GOGGLES AND ADE-
QUATE PROTECTIVE CLOTHING WHEN SERVICING
FUEL SYSTEM.
(8) Start engine and check for leaks.
(9) Install engine cover (Refer to 9 - ENGINE
COVER - INSTALLATION).
FUEL PRESSURE SENSOR
DESCRIPTION
The fuel pressure sensor monitors and passes on
the current rail pressure to the control module (Fig.
11). The non-constant system pressure influences the
position of the sensor diaphragm which alters the
sensors electrical resistance.
OPERATION
The rail pressure sensor measures the current rail
pressure and supplies an appropriate voltage signal
to the Engine Control Module (ECM). The pressure
control valve is then actuated by the ECM through a
control loop until the desired rail pressure is reached.
Fig. 11 FUEL RAIL AND FUEL PRESSURE SENSOR
LOCATIONS
1 - FUEL PRESSURE SENSOR
2 - FUEL RAIL
14 - 24
FUEL INJECTION
PT
FUEL INJECTOR (Continued)
REMOVAL
WARNING: HIGH-PRESSURE FUEL LINES DELIVER
FUEL UNDER EXTREME PRESSURE FROM THE
INJECTION
PUMP
TO
THE
INJECTORS.
THIS
MAYBE AS HIGH AS 1600BAR (23,200PSI). USE
EXTREME CAUTION WHEN INSPECTING FOR HIGH-
PRESSURE
FUEL
LEAKS.
FUEL
UNDER
THIS
AMOUNT OF PRESSURE CAN PENETRATE SKIN
CAUSING PERSONAL INJURY OR DEATH. INSPECT
HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF
CARDBOARD. WEAR SAFETY GOGGLES AND ADE-
QUATE PROTECTIVE CLOTHING WHEN SERVICING
FUEL SYSTEM.
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE
COVER - REMOVAL).
(3) Disconnect fuel pressure sensor electrical con-
nector (Fig. 11).
(4) Remove fuel pressure sensor from fuel rail (Fig.
11).
INSTALLATION
WARNING: HIGH-PRESSURE FUEL LINES DELIVER
FUEL UNDER EXTREME PRESSURE FROM THE
INJECTION
PUMP
TO
THE
INJECTORS.
THIS
MAYBE AS HIGH AS 1600BAR (23,200PSI). USE
EXTREME CAUTION WHEN INSPECTING FOR HIGH-
PRESSURE
FUEL
LEAKS.
FUEL
UNDER
THIS
AMOUNT OF PRESSURE CAN PENETRATE SKIN
CAUSING PERSONAL INJURY OR DEATH. INSPECT
HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF
CARDBOARD. WEAR SAFETY GOGGLES AND ADE-
QUATE PROTECTIVE CLOTHING WHEN SERVICING
FUEL SYSTEM.
(1) Install fuel pressure sensor into fuel rail (Fig.
11).
(2) Connect fuel pressure sensor electrical connec-
tor (Fig. 11).
(3) Install engine cover (Refer to 9 - ENGINE
COVER - INSTALLATION).
(4) Connect negative battery cable.
INTAKE AIR TEMPERATURE
SENSOR
DESCRIPTION
This sensor is used to monitor the intake air tem-
perature (Fig. 12).
OPERATION
The intake air temperature sensor is a negative
temperature coefficient (NTC) thermistor (resistance
varies with temperature). This means at cold air
temperature its resistance is high, so the voltage sig-
nal will be high. As intake air temperature increases,
sensor resistance decreases and the signal voltage
will be low. This allows the sensor to provide an ana-
log voltage signal (0.2-4.8 volts) to the ECM.
Fig. 12 SENSOR LOCATIONS
1 - BOOST PRESSURE SENSOR
2 - CRANKSHAFT POSITION (CKP) SENSOR
3 - INTAKE AIR TEMPERATURE SENSOR
PT
FUEL INJECTION
14 - 25
FUEL PRESSURE SENSOR (Continued)
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