Chrysler PT Cruiser. Manual — part 217
FUEL DELIVERY
TABLE OF CONTENTS
page
page
FUEL DELIVERY
DIAGNOSIS AND TESTING - FUEL DELIVERY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUEL DRAIN TUBES
. . . . . . . . . . . . . . . . . . . . . . . . . . 7
FUEL INJECTION PUMP
. . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . . . . . . . . . 9
FUEL RAIL
. . . . . . . . . . . . . . . . . . . . . . . . . . 9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . . . . . . . . . . . . . . . . . . . . . . . 10
FUEL LINES
INSTALLATION - HIGH PRESSURE LINES
FUEL TANK
. . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FUEL PUMP MODULE
DESCRIPTION - FUEL PUMP MODULE
. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
FUEL FILTER/FUEL HEATER
. . . . . . . . . . . . . . . . . . . . . . . . . 13
DIAGNOSIS AND TESTING - FUEL FILTER
DIAGNOSIS AND TESTING - FUEL HEATER
. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
. . . . . . . . . . . . . . . 15
. . . . . . . . . . . . . . . . . . . . . . . 16
FUEL DELIVERY
DIAGNOSIS AND TESTING - FUEL DELIVERY
SYSTEM
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.
CONDITION
POSSIBLE CAUSES
CORRECTION
No Start/Hard Start/Start
and Stall
Contaminated Fuel
Drain, Flush and Refill Fuel
System
Low Fuel Pressure to Fuel Filter
Test Fuel Pump Pressure
Restricted Fuel Filter
Replace Fuel Filter
Fuel Heater Inoperative
Test Fuel Heater and circuitry
Restricted or Leaking Fuel Lines
Inspect/ Replace necessary fuel
line(s)
Stored Diagnostic Trouble Codes
Refer to the appropriate
Diagnostic Service Manual
Stalls Under Aggressive
Maneuvers/Loss Of Fuel
Pressure
Restricted or Damaged Fuel Pump
Lower Filter
Test Fuel Pump Pressure
Contaminated Fuel
Drain, Flush and Refill Fuel
System
Damaged Fuel Tank
Replace Fuel Tank
14 - 6
FUEL DELIVERY
PT
CONDITION
POSSIBLE CAUSES
CORRECTION
Restricted Fuel Filter
Replace Fuel Filter
Cannot Refill Fuel
Tank/Excessive Pressure in
Fuel Tank When Cap Is
Removed
Sticking or Damaged Fuel Tank
Fill/Vent Valve
Replace Fuel Tank
Restricted or Damaged Fuel Tank
Fill/Vent Valve Filter or Hose
Replace Fuel Tank Vent Filter
FUEL DRAIN TUBES
DESCRIPTION
The fuel drain tubes connect to the top of all four
injectors (Fig. 1). These tubes are used to return
unused fuel from the fuel injectors to the fuel filter.
FUEL INJECTION PUMP
DESCRIPTION
The fuel injection pump is a radial piston pump
with three pistons arranged at an angle of 120°. The
injection pump is driven by the intake camshaft. The
pump is mounted to the rear of the cylinder head
(Fig. 2).
OPERATION
LOW PRESSURE SIDE
The fuel supplied by the fuel delivery pump flows
through the fuel feed to the throttle valve. Any air
entrained by the fuel is directed through the restric-
tor to the return flow. The throttle valve opens
against the force of the spring at a pressure of
Fig. 1 FUEL SYSTEM COMPONENTS
1 - FUEL INJECTOR
2 - FUEL PRESSURE SOLENOID
3 - FUEL RETURN TO FILTER
4 - FUEL RETURN TO INJECTION PUMP
5 - FUEL RAIL
6 - HIGH PRESSURE FUEL LINE FROM PUMP TO RAIL
7 - FUEL PRESSURE SENSOR
8 - HIGH PRESSURE LINE FROM RAIL TO INJECTOR
9 - FUEL DRAIN TUBES
Fig. 2 INJECTION PUMP LOCATION
1 - INJECTION PUMP
2 - VACUUM PUMP
3 - EGR VALVE
4 - CYLINDER HEAD COVER
PT
FUEL DELIVERY
14 - 7
FUEL DELIVERY (Continued)
approx. 0.4 bar and the fuel is able to flow along a
ring line to the individual pistons. The eccentric
shaft with its eccentric plate moves the pistons up
and down against the piston spring of the three
pump elements. The leak fuel from the pistons flows
along the return flow to the fuel tank. The fuel flow-
ing out of the throttle valve, also flows off along the
return flow.
HIGH PRESSURE SIDE
A. Filling the piston: The piston is moved down
as a result of the piston spring. The fuel supplied by
the fuel delivery pump flows along the ring passage,
the valve disk and the valve spring into the cylinder.
The ball valve prevents the fuel from being able to
flow back from the high pressure passage.
B. Producing high pressure:The piston is moved
up by the rising eccentric shaft and the fuel is thus
compressed. The valve disk shuts off the delivery vol-
ume to the fuel feed. Once the fuel pressure in the
cylinder rises beyond the pressure which exists in
the high pressure circuit, the ball valve opens and
the fuel is pumped into the high pressure circuit.
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 MAF sensor electrical connector.
(4) Disconnect air inlet hose from air cleaner hous-
ing.
(5) Remove air cleaner housing assembly by pull-
ing straight up out of mounts (Refer to 9 - ENGINE/
AIR INTAKE SYSTEM/AIR CLEANER HOUSING -
REMOVAL).
(6) Remove fuel line retainer and retaining bolt
from pump. Disconnect fuel supply and return lines
at pump (Fig. 3).
(7) Disconnect high pressure fuel line from pump
to rail at injection pump (Fig. 3).
(8) Remove injection pump retaining bolts and
remove pump from cylinder head (Fig. 4).
Fig. 3 INJECTION PUMP FUEL LINES
1 - RETURN LINE FROM FUEL RAIL
2 - INJECTION PUMP FEED LINE
3 - INJECTION PUMP
4 - HIGH PRESSURE LINE TO FUEL RAIL
Fig. 4 INJECTION PUMP RETAINING BOLTS
1 - INJECTION PUMP
2 - INJECTION PUMP RETAINING BOLTS
3 - HIGH PRESSURE LINE TO FUEL RAIL
14 - 8
FUEL DELIVERY
PT
FUEL INJECTION PUMP (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.
(1) Align injection pump with pump drive and
slide into cylinder head.
(2) Install retaining bolts (Fig. 4). Torque to 14N·m
(124 lbs. in.).
(3) Install fuel supply and return lines to injection
pump (Fig. 3). Install bracket and retaining bolt.
Torque bolt to 9N·m (80 lbs. in.).
(4) Connect high pressure fuel line to fuel rail at
injection pump. Torque line to 22N·m (16 lbs.ft.).
(5) Install air cleaner housing assembly (Refer to 9
- ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
HOUSING - INSTALLATION).
(6) Connect air cleaner inlet hose.
(7) Connect MAF sensor electrical connector.
(8) 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.
(9) Start engine and check for leaks.
(10) Install engine cover (Refer to 9 - ENGINE
COVER - INSTALLATION).
FUEL RAIL
DESCRIPTION
The fuel rail acts like a high pressure store. It is
available to all injectors for drawing fuel which has
been compressed by the injection pump. The rail
pressure sensor, rail pressure solenoid, high pressure
line, and the return flow line are attached to the fuel
rail (Fig. 5).
OPERATION
The stored fuel volume inside the rail acts as a
damper
for
pressure
fluctuations
which
result
because of pulsating supply and brief large extrac-
tions of fuel during injector firing. The rail primarily
influences the atomization of fuel at the injector noz-
zle, and the accuracy of injected quantity during
injection.
Fig. 5 FUEL SYSTEM COMPONENTS
1 - FUEL INJECTOR
2 - FUEL PRESSURE SOLENOID
3 - FUEL RETURN TO FILTER
4 - FUEL RETURN TO INJECTION PUMP
5 - FUEL RAIL
6 - HIGH PRESSURE FUEL LINE FROM PUMP TO RAIL
7 - FUEL PRESSURE SENSOR
8 - HIGH PRESSURE LINE FROM RAIL TO INJECTOR
9 - FUEL DRAIN TUBES
PT
FUEL DELIVERY
14 - 9
FUEL INJECTION PUMP (Continued)
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