Chrysler PT Cruiser. Manual — part 219
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - FUEL FILTER
WARNING: NO SPARKS, OPEN FLAMES OR SMOK-
ING. RISK OF POISONING FROM INHALING AND
SWALLOWING FUEL. RISK OF INJURY TO EYES
AND SKIN FROM CONTACT WITH FUEL. POUR
FUELS ONLY INTO SUITABLE AND APPROPRI-
ATELY MARKED CONTAINERS. WEAR PROTECTIVE
CLOTHING.
This diagnostic will test for a failing fuel pump or
restricted fuel filter.
(1) Disconnect the negative battery cable.
(2) Disconnect the fuel supply line to the fuel fil-
ter/fuel heater assembly, at the filter assembly.
NOTE: Obtain the correct Fuel Line Pressure Test
Adapter Tool Hose. Tool number 6539 is used for
5/16” fuel lines and tool number 6631 is used for
3/8”lines.
(3) Connect correct Fuel Line Pressure Test Adap-
tor Tool Hose between the disconnected fuel line and
filter/heater assembly (Fig. 11).
(4) Connect the 0-4.1bar (0-60 psi.) fuel pressure
gauge (from Gauge Set 5069) to the test port on the
appropriate Adaptor Tool.
(5) Connect negative battery cable.
(6) Crank or run engine and record the fuel pres-
sure reading.
(7) Turn off the ignition (fuel pressure should
begin to bleed down immediately).
(8) Disconnect negative battery cable.
WARNING: THERE MAY BE FUEL IN THE PRES-
SURE TEST ADAPTOR TOOL HOSE, WRAP SHOP
TOWELS AROUND HOSES TO CAPTURE ANY FUEL
SPILLAGE.
(9) Disconnect Fuel Line Pressure Adaptor Tool
Hose.
(10) Reconnect fuel tank supply line to fuel filter/
fuel heater assembly.
(11) Disconnect fuel supply line to injector pump,
at the fuel filter/fuel heater assembly (Fig. 12).
(12) Connect Fuel Line Pressure Test Adaptor Tool
Hose between the disconnected fuel line and filter/
heater assembly.
(13) Connect negative battery cable.
(14) Crank or run engine and record the fuel pres-
sure reading.
(15) Turn off the ignition.
(16) Disconnect negative battery cable.
(17) Reconnect the fuel supply line to the fuel fil-
ter/fuel heater.
Fig. 11 FUEL PRESSURE GAUGE
1 - FUEL FILTER/FUEL HEATER
2 - FUEL PRESSURE TEST HOSE
3 - FUEL PRESSURE GAUGE
4 - CONNECT TO FUEL TANK SUPPLY LINE
Fig. 12 FUEL PRESSURE GAUGE
1 - FUEL FILTER/FUEL HEATER
2 - FUEL PRESSURE GAUGE
3 - FUEL LINE PRESSURE TEST ADAPTOR HOSE
4 - CONNECT TO INJECTOR PUMP FUEL SUPPLY LINE
14 - 14
FUEL DELIVERY
PT
FUEL FILTER/FUEL HEATER (Continued)
Inspect fuel lines and fuel tank for leaks and dam-
age, replace the fuel pump module if the first pres-
sure reading test did not obtain 1.5bar (22 psi.).
Retest system after repair.
Replace the fuel filter if the pressure difference
between test one and test two is more than 0.5bar (8
psi.).
DIAGNOSIS AND TESTING - FUEL HEATER
CONDITION
POSSIBLE CAUSES
CORRECTION
Fuel Heater Inoperative
No ignition positive voltage to heater.
Open or Shorted ignition
positive voltage circuit.
Poor connector terminal end
connection.
No fuel heater ground.
Open or Shorted ground circuit.
Poor connector terminal end
connection.
Open fuel heater element.
Replace fuel filter/fuel heater
assembly.
REMOVAL
REMOVAL
WARNING: THERE IS FUEL PRESENT IN THE FIL-
TER HOUSING. REMOVE HOSES, AND HANDLE
THE FILTER HOUSING CAREFULLY TO REDUCE
SPLASH.
NOTE: Use a shop towel to capture any residual
fuel spillage during this procedure.
(1) Disconnect negative battery cable.
(2) Disconnect fuel supply line form fuel tank.
(3) Disconnect fuel supply line to injection pump.
(4) Disconnect both fuel return lines from pressure
regulator.
(5) Disconnect fuel heater electrical connector.
(6) Remove the right ECM mounting bracket to
dash panel screws.
(7) Carefully pull back on the ECM mounting
bracket and remove fuel filter housing retaining
screws and filter housing from vehicle.
REMOVAL - FUEL FILTER
WARNING: NO SPARKS, OPEN FLAMES, OR SMOK-
ING. RISK OF POISONING FROM INHALING AND
SWALLOWING FUEL. RISK OF INJURY TO EYES
AND SKIN FROM CONTACT WITH FUEL. POUR
FUELS ONLY INTO SUITABLE AND APPROPRI-
ATELY MARKED CONTAINERS. WEAR PROTECTIVE
CLOTHING.
(1) Disconnect negative battery cable.
NOTE: Use a shop towel to capture any residual
fuel spillage during this procedure.
(2) Unscrew the fuel filter element from the top of
the housing and discard (Fig. 10).
Fig. 13 FUEL FILTER HOUSING ASSEMBLY
1 - FUEL FILTER
2 - FUEL FILTER HOUSING
3 - FUEL HEATER
4 - ECM BRACKET
PT
FUEL DELIVERY
14 - 15
FUEL FILTER/FUEL HEATER (Continued)
INSTALLATION
INSTALLATION
NOTE: Use shop towels to capture any residual fuel
spillage during this procedure.
(1) Position the fuel filter housing against ECM
mounting bracket and install screws. Tighten screws
to 28N·m (250 lbs.in.). (Fig. 13).
(2) Position and install the ECM bracket. Tighten
ECM mounting bracket retaining screws to 12 N·m.
(115 lbs.in.).
(3) Connect fuel heater electrical connector.
(4) Connect both fuel return lines to pressure reg-
ulator.
(5) Connect fuel supply line to injector pump.
(6) Connect fuel supply line to fuel tank.
(7) Connect negative battery cable.
(8) Start engine and inspect for leaks.
INSTALLATION - FUEL FILTER
WARNING: NO SPARKS, OPEN FLAMES, OR SMOK-
ING. RISK OF POISONING FROM INHALING AND
SWALLOWING FUEL. RISK OF INJURY TO EYES
AND SKIN FROM CONTACT WITH FUEL. POUR
FUELS ONLY INTO SUITABLE AND APPROPRI-
ATELY MARKED CONTAINERS. WEAR PROTECTIVE
CLOTHING.
(1) Lubricate new fuel filter element seal with
clean diesel fuel and screw into housing.
(2) Torque fuel filter element to 35N·m (310 lbs.
in.).
(3) Connect negative battery cable.
(4) Start engine and inspect for leaks.
14 - 16
FUEL DELIVERY
PT
FUEL FILTER/FUEL HEATER (Continued)
FUEL INJECTION
TABLE OF CONTENTS
page
page
FUEL INJECTION
STANDARD PROCEDURE - TESTING FUEL
. . . . . . . . . . . . . . . . . . . . . . . . . . 17
ACCELERATOR PEDAL POSITION SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . 18
BOOST PRESSURE SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . 19
CRANKSHAFT POSITION SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
FUEL INJECTOR
. . . . . . . . . . . . . . . . . . . . . . . . . 20
. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . 21
CLASSIFICATION . . . . . . . . . . . . . . . . . . . . . 21
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
. . . . . . . . . . . . . . . . . . . . . . . . . 23
FUEL PRESSURE SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
. . . . . . . . . . . . . . . . . . . . . . . . . 25
INTAKE AIR TEMPERATURE SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . 25
. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
CAMSHAFT POSITION SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . 26
. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
. . . . . . . . . . . . . . . . . . . . . . . . . 26
MANIFOLD AIR FLOW (MAF) SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . 26
. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
. . . . . . . . . . . . . . . . . . . . . . . . . 27
FUEL PRESSURE SOLENOID
. . . . . . . . . . . . . . . . . . . . . . . . . 27
. . . . . . . . . . . . . . . . . . . . . . . . . . . 27
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
. . . . . . . . . . . . . . . . . . . . . . . . . 29
SWIRL ACTUATOR
DESCRIPTION - INTAKE MANIFOLD SWIRL
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DESCRIPTION - SWIRL VALVE ACTUATOR
SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . 30
OPERATION - INTAKE MANIFOLD SWIRL
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . 30
FUEL INJECTION
STANDARD PROCEDURE - TESTING FUEL
INJECTORS
WARNING:
AVOID
ALL
CONTACT
WITH
FUEL
SPRAY. THE HIGH PRESSURE PUMP SUPPLIES
HIGH-PRESSURE
FUEL
TO
EACH
INDIVIDUAL
INJECTOR
THROUGH
HIGH-PRESSURE
LINES.
FUEL UNDER THIS AMOUNT OF PRESSURE CAN
PENETRATE SKIN AND CAUSE PERSONAL INJURY.
WEAR SAFETY GOGGLES AND ADEQUATE PRO-
TECTIVE CLOTHING WHEN SERVICING FUEL SYS-
TEM.
NOTE: The fuel pump pressure must be 1.5 bar (22
psi.), and the engine must be at operating tempera-
ture 80°C (176°F).
(1) Run the engine until operating temperature is
obtained.
(2) Turn OFF the ignition.
(3) Disconnect the fuel injector return hose at the
return hose fitting directly below the fuel pressure
solenoid (Fig. 1).
(4) Block off fuel return fitting at the fuel rail.
(5) Place the fuel return hose into a suitable con-
tainer.
(6) Start the engine and measure the amount of
return fuel into the container for one minute at idle.
PT
FUEL INJECTION
14 - 17
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