Chrysler RG Voyager. Manual — part 492
DIAGNOSIS AND TESTING - FUEL HEATER
The fuel heater element only operates between 8°C
(46°F) and 24°C (76°F).
CONDITION
POSSIBLE CAUSES
CORRECTION
Fuel Heater Inoperative
Open or shorted battery positive
circuit to fuel heater relay.
Test and repair circuit as
required.
Open or shorted ignition positive
voltage circuit to fuel heater relay.
Test and repair circuit as
required.
Open or shorted fuel heater relay
ground circuit.
Test and repair circuit as
required.
Open or shorted fuel heater relay
output circuit.
Test and repair circuit as
required.
Faulty fuel heater relay
Test and replace as necessary.
Faulty fuel heater
Test and replace as necessary.
Faulty ECM
Test and replace as necessary.
REMOVAL
(1) The Fuel Heater is part of the Fuel Filter/Wa-
ter Separator. Refer to the Fuel Filter/Water Separa-
tor Replacement Procedure (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/FUEL FILTER / WATER
SEPARATOR - REMOVAL).
INSTALLATION
(1) The Fuel Heater is part of the Fuel Filer/Water
Separator. Refer to the Fuel Filter/Water Separator
Installation Procedure (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/FUEL FILTER / WATER SEPA-
RATOR - INSTALLATION).
14a - 16
FUEL DELIVERY
RG
FUEL HEATER (Continued)
FUEL INJECTION
TABLE OF CONTENTS
page
page
FUEL INJECTION
STANDARD PROCEDURE - TESTING FUEL
. . . . . . . . . . . . . . . . . . . . . . . . . . 17
FUEL PRESSURE SOLENOID
. . . . . . . . . . . . . . . . . . . . . . . . . 18
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
. . . . . . . . . . . . . . . . . . . . . . . . . 19
FUEL INJECTOR
. . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
STANDARD PROCEDURE - INJECTOR BORE
. . . . . . . . . . . . . . . . . . . . . . . . . . . 21
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
. . . . . . . . . . . . . . . . . . . . . . . . . 22
ACCELERATOR PEDAL POSITION SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . 23
. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
REMOVAL - PEDAL POSITION SENSOR (LHD)
INSTALLATION - PEDAL POSITION SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
BOOST PRESSURE SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
PRESSURE/INTAKE AIR TEMPERATURE
SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INTAKE AIR TEMPERATURE SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
. . . . . . . . . . . . . . . . . . . . . . . . . 25
CRANKSHAFT POSITION SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . 25
. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
MASS AIR FLOW (MAF) SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . 25
. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
. . . . . . . . . . . . . . . . . . . . . . . . . 26
FUEL INJECTION
STANDARD PROCEDURE - TESTING FUEL
INJECTORS
NOTE: The fuel pump pressure must be between
0.8 and 1.2 bar (13–17 psi), and engine must be at
operating temperature, engine coolant 88°C (190°F).
(1) (Refer to 14 - FUEL SYSTEM - WARNING).
Run engine until operating temperature is obtained.
(2) Turn Off the ignition.
(3) Disconnect the fuel injector fuel return hose at
the return hose tee directly behind the generator,
next to the air purge fitting, leaving the return hose
to the high pressure injection pump connected to the
pump (Fig. 1).
(4) Block off fuel return line to high pressure injec-
tion pump.
(5) Connect a hose to the return hose tee and place
it in a suitable container.
(6) Start the engine and measure the return fuel
for 1 minute at idle.
NOTE: If the quantity of fuel is above 100ml. it
means one or more of the fuel injectors has a prob-
lem.
(7) If the measured quantity is above 100ml, dis-
connect each individual injector and measure the
quantity of return fuel into the container.
NOTE: Make sure to block off the fuel return hose
at each individual fuel injector before taking a mea-
surement.
(8) Replace the fuel injector that has a return rate
above 25ml. for one minute at idle(Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - REMOVAL).
(9) If the test does not give a positive result, dis-
connect the fuel return line at the fuel rail. If fuel is
present, replace the fuel rail (Refer to 14 - FUEL
SYSTEM/FUEL
DELIVERY/FUEL
RAIL
-
REMOVAL).
RG
FUEL INJECTION
14a - 17
(10) Perform the fuel system air purge procedure
after replacing any components (Refer to 14 - FUEL
SYSTEM - STANDARD PROCEDURE).
FUEL PRESSURE SOLENOID
DESCRIPTION
The fuel pressure solenoid controls the low pres-
sure fuel supply to the high pressure injection pump.
The readings along with the Fuel Pressure Sensor
readings are used by the ECM to determine and
maintain the appropriate fuel system pressure under
all driving conditions (Fig. 2).
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Lift up on the power steering pump reservoir,
and remove it from it’s mounting. Place the reservoir
aside.
(4) (Refer to 14 - FUEL SYSTEM - WARNING).
Thoroughly clean the high pressure fuel injection
pump around the area of the fuel pressure solenoid
and use compressed air to dry (Fig. 2).
(5) Disconnect the fuel pressure solenoid electrical
connector (Refer to 14 - FUEL SYSTEM - WARN-
ING).
(6) Remove the screw attaching the solenoid to the
pump (Refer to 14 - FUEL SYSTEM - WARNING).
(7) Grab the fuel pressure solenoid, twist, and pull
back to remove the solenoid from the pump (Refer to
14 - FUEL SYSTEM - WARNING).
NOTE: DO NOT use mechanical implements to
remove dirt and debris from the injection pump
bores or mating surfaces.
(8) Use a clean, lint free cloth to remove any
debris from the bores and mating surfaces of the
injection pump.
Fig. 1 DIESEL FUEL SYSTEM COMPONENTS
1 - HIGH PRESSURE FUEL INJECTION PUMP
2 - FUEL PRESSURE SOLENOID
3 - AIR PURGE FITTING
4 - FUEL INJECTOR FUEL RETURN HOSE TEE
5 - HIGH PRESSURE FUEL SUPPLY LINE
6 - FUEL INJECTOR
7 - FUEL RAIL
8 - FUEL RAIL PRESSURE SENSOR
9 - FUEL RAIL RETURN LINE
Fig. 2 FUEL PRESSURE SOLENOID
1 - FUEL RETURN LINE
2 - HIGH PRESSURE FUEL INJECTION PUMP
3 - FUEL PRESSURE SOLENOID
4 - ACCESSORY BRACKET
14a - 18
FUEL INJECTION
RG
FUEL INJECTION (Continued)
INSTALLATION
(1) Inspect O-rings on the new pressure solenoid
for any damage and ensure that the O-rings are
seated properly (Refer to 14 - FUEL SYSTEM -
WARNING).
(2) Coat both O-rings with clean engine oil or die-
sel fuel.
NOTE: If pressure solenoid is pressed in at an
angle, the O-rins may be damaged, resulting in fuel
leakage or high pressure injection pump malfunc-
tion.
(3) Position the new pressure solenoid horizontally
into the high pressure injection pump, twist slightly
while pressing into pump. Ensure the mating sur-
faces of both components are flush (Fig. 2).
(4) Install the pressure solenoid retaining screws
by hand and tighten in 2 phases. 3 - 4Nm (27 -
35lbs.in.) then 6 - 7Nm (53 - 62 lbs.in.).
(5) Connect the pressure solenoid electrical connec-
tor.
(6) Install the power steering reservoir into it’s
mounting bracket.
(7) Connect the negative battery cable.
(8) Perform the Fuel System Air Purge procedure
(Refer to 14 - FUEL SYSTEM - STANDARD PROCE-
DURE).
FUEL INJECTOR
DESCRIPTION
FUEL INJECTOR
WARNING: HIGH - PRESSURE FUEL LINE DELIVER
DIESEL FUEL UNDER EXTREME PRESSURE FROM
THE INJECTION PUMP TO THE FUEL INJECTORS.
THIS MAY BE 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 FOR HIGH - PRESSURE LEAKS WITH A
SHEET OF CARDBOARD. WEAR SAFETY GOG-
GLES AND ADEQUATE PROTECTIVE CLOTHING
WHEN SERVICING FUEL SYSTEM.
(Refer to 14 - FUEL SYSTEM - WARNING) There
are individual fuel injectors for all four cylinders.
These fuel injectors are used to spray fuel into the
combustion chamber (Fig. 3).
OPERATION
(Refer to 14 - FUEL SYSTEM - WARNING) The
injector operation can be subdivided into four operat-
ing states with the engine running and the high-
pressure pump generating pressure:
• Injector closed (with high pressure applied)
• Injector opens (start of injection)
• Injector opened fully
• Injector closes (end of injection)
Injector closed (with high pressure applied)
With the injector closed (at-rest state), the solenoid
valve is not energized and is therefore closed. With
the bleed orifice closed, the valve spring forces the
armature’s ball onto the bleed-orifice seat. The rail’s
high pressure build up in the valve control chamber,
and the same pressure is also present in the nozzle’s
chamber volume. The rail pressure applied at the
control plunger’s end face, together with the force of
the nozzle spring, maintain the nozzle in the closed
position against the opening forces applied to its
pressure stage (Fig. 4).
Fig. 3 FUEL INJECTOR
1 - FUEL INJECTOR
2 - NOZZLE
3 - FUEL INLET FITTING
4 - ELECTRICAL CONNECTION
RG
FUEL INJECTION
14a - 19
FUEL PRESSURE SOLENOID (Continued)
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