Chrysler Town, Dodge Caravan. Manual — part 1107
(13) Install power steering belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
INSTALLATION).
(14) Install air cleaner housing assembly.
(15) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(16) Connect negative battery cable (Refer to 14 -
FUEL SYSTEM - WARNING).
FUEL LINES
DESCRIPTION
DESCRIPTION
All fuel lines up to the high pressure pump are
considered low-pressure. This includes the fuel lines
from the fuel tank to the fuel/lift pump, and the fuel/
lift pump to the high pressure pump. The fuel return
lines and the fuel drain lines are also considered low-
pressure lines. High-pressure lines are used between
the high pressure pump and the fuel rail and then
from the rail to the fuel injectors. Also refer to High-
Pressure Fuel Lines Description/Operation.
DESCRIPTION - HIGH PRESSURE FUEL LINES
(Refer to 14 - FUEL SYSTEM - WARNING). The
high-pressure fuel lines are used between the fuel
injection pump and the fuel injector rail, and
between the fuel injection rail and fuel injectors. All
other fuel lines are considered low-pressure lines
OPERATION - HIGH PRESSURE FUEL LINES
WARNING:: HIGH - PRESSURE LINES DELIVER DIE-
SEL FUEL UNDER EXTREME PRESSURE FROM
THE INJECTION PUMP TO THE FUEL INJECTORS.
THIS MAY BE AS HIGH AS 1600BAR (23,200 PSI.).
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 FUEL LEAKS
WITH A SHEET OF CARDBOARD. WEAR SAFETY
GOGGLES AND ADEQUATE PROTECTIVE CLOTH-
ING WHEN SERVICING FUEL SYSTEM.
Fig. 8 VM.1067 INSTALLATION
1 - TIMING BELT
2 - INJECTION PUMP SPROCKET
3 - FLANGE OF VM.1067
4 - INNER TIMING BELT COVER
Fig. 9 INJECTION PUMP/GEAR REMOVAL USING
VM.1067
1 - TIMING BELT
2 - INNER TIMING BELT COVER
3 - INJECTION PUMP SPROCKET HOLDING PLATE ASSEMBLY
PART OF VM.1067
4 - INJECTION PUMP SPROCKET
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FUEL DELIVERY
14 - 11
FUEL INJECTION PUMP (Continued)
CAUTION: The high-pressure fuel lines cannot con-
tact each other or other components. Do not
attempt to weld high-pressure fuel lines or to repair
lines that are damaged. If lines are ever kinked or
bent, they must be replaced. Use only the recom-
mended lines when replacement of high-pressure
fuel line is necessary.
High-pressure
fuel
lines
deliver
fuel
under
extremely high pressure from the high pressure
pump to the fuel injectors (Refer to 14 - FUEL SYS-
TEM - WARNING). The lines expand and contract
from the high-pressure fuel pulses generated during
the injection process. All high-pressure fuel lines are
of the same length and inside diameter. Correct high-
pressure fuel line usage and installation is critical to
smooth engine operation.
DIAGNOSIS AND TESTING - HIGH PRESSURE
FUEL LINES
(Refer to 14 - FUEL SYSTEM - WARNING). High-
pressure fuel line leaks can cause starting problems
and poor engine performance.
WARNING: DUE TO EXTREME FUEL PRESSURES,
USE EXTREME CAUTION WHEN INSPECTING FOR
HIGH-PRESSURE FUEL LEAKS. DO NOT GET YOUR
HAND NEAR A SUSPECTED LEAK. INSPECT FOR
HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF
CARDBOARD. HIGH FUEL INJECTION PRESSURE
CAN CAUSE PERSONAL INJURY IF CONTACT IS
MADE WITH THE SKIN.
Start the engine. Move the cardboard over the
high-pressure fuel lines and check for fuel spray onto
the cardboard (Fig. 11). If a high-pressure line con-
nection is leaking, tighten the connection and per-
form the Fuel System Air Purge procedure (Refer to
14 - FUEL SYSTEM - STANDARD PROCEDURE).
Replace damaged, restricted or leaking high-pressure
fuel lines with the correct replacement line.
CAUTION: The high-pressure fuel lines cannot con-
tact each other or other components. Do not
attempt to weld high-pressure fuel lines or to repair
lines that are damaged. Only use the recommended
lines when replacement of high-pressure fuel line is
necessary.
Fig. 10 INJECTION PUMP REMOVAL
1 - FUEL SUPPLY HOSE
2 - BANJO BOLT
3 - WASHER
4 - FUEL PRESSURE SOLENOID
5 - HIGH PRESSURE INJECTION PUMP
6 - INJECTION PUMP GEAR
7 - WASHERS
8 - BANJO BOLT
9 - FUEL RETURN HOSE
Fig. 11 Typical Test for Leaks with Cardboard
1 - HIGH-PRESSURE LINE
2 - CARDBOARD
3 - FITTING
14 - 12
FUEL DELIVERY
RG
FUEL LINES (Continued)
FUEL/LIFT PUMP RELAY
DESCRIPTION
The fuel/lift pump relay is located in the Inte-
grated Power Module (IPM). This micro-relay oper-
ates the same as a conventional relay except the
terminal orientation and current capacity is different,
and the relay case is smaller.
OPERATION
Fused battery positive voltage is supplied to the
fuel/lift pump relay at all times through the Inte-
grated Power Module (IPM). Fused ignition positive
voltage is supplied to the fuel/lift pump relay through
the IPM. The fuel/lift pump is grounded to the chas-
sis. When the ignition switch is in the Run or Start
position, the ECM grounds the lift pump relay con-
trol circuit for 30 to 45 seconds. This closes the relay
contacts and supplys power to the fuel/lift pump
motor. The fuel/lift pump will only operate on inital
key On.
FUEL/LIFT PUMP
DESCRIPTION
The fuel/lift pump is located under the vehicle in
front of the rear axle assembly (Fig. 12). The 12–volt
electric vane-type pump is operated and controlled by
the Engine Control Module (ECM).
OPERATION
The purpose of the fuel/lift pump is to supply a
low-pressure
fuel
source:
from
the
fuel
tank,
through the fuel filter/water separator and to the
high pressure pump.
Fused battery positive voltage is supplied to the
fuel/lift pump relay at all times through the Inte-
grated Control Module. Fused ignition positive volt-
age is supplied to the fuel/lift pump relay by the
ECM. When the ignition key is turned to the Run or
Start position, the ECM grounds the relay control
circuit for 5 seconds, which closes the relay contacts
and allows fuel pump operation.
With the ignition “ON” and fuel transfer pump
running, the low-pressure fuel pressure should be
13-17 psi.
Fig. 12 FUEL TRANSFER(LIFT) PUMP LOCATION
1 - LIFT PUMP RETAINING BOLTS
2 - LIFT PUMP
3 - FUEL FILTER/WATER SEPARATOR HOUSING
4 - FUEL HEATER
5 - CHECK BALL
6 - O-RING
7 - FLOW DIVERTER
8 - FUEL FILTER
9 - O-RING
10 - FUEL FILTER BOWL ASSEMBLY
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FUEL DELIVERY
14 - 13
DIAGNOSIS AND TESTING - FUEL/LIFT PUMP
CONDITION
POSSIBLE CAUSES
CORRECTION
Fuel/Lift Pump Inoperative
Stored DTC’s
Refer to the appropriate
diagnostic manual
Open or shorted fused ignition switch
output circuit.
Test and repair circuit as
required
Open or shorted fused battery
voltage circuit to fuel/lift pump relay.
Test and repair circuit as
required.
Open or shorted fuel/lift pump relay
output circuit.
Test and repair circuit as
required.
Open or high resistance, fuel/lift
pump ground circuit.
Test and repair circuit as
required.
Defective fuel/lift pump relay
Test and replace relay as
required.
Defective fuel/lift pump
Replace fuel/lift pump
REMOVAL
(1) The fuel pump is serviced as part of the fuel
filter/water separator assembly. Refer to (Refer to 14
- FUEL SYSTEM/FUEL DELIVERY/FUEL FILTER /
WATER SEPARATOR - REMOVAL).
INSTALLATION
(1) The fuel pump is serviced as an assembly along
with the fuel filter/water separator. Refer to (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/FUEL FIL-
TER / WATER SEPARATOR - INSTALLATION).
WATER IN FUEL SENSOR
DESCRIPTION
The WIF sensor is located in the bowl assembly of
the fuel filter/water separator.
OPERATION
The sensor sends an input to the Engine Control
Module (ECM) when it senses water in the fuel filter/
water separator. As the water level in the filter/sep-
arator increases, the resistance across the WIF
sensor decreases. This decrease in resistance is sent
as a signal to the ECM and compared to a high
water standard value. Once the value reaches 30 to
40 kilohms, the ECM will activate the water-in-fuel
warning lamp. This all takes place when the ignition
key is initially put in the ON position. The ECM con-
tinues to monitor the input at the end of the intake
manifold air heater post-heat cycle.
REMOVAL
The Water in Fuel Sensor is part of the fuel filter
bowl assembly. Refer to fuel filter replacement for
removal procedure (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/FUEL FILTER / WATER SEPA-
RATOR - REMOVAL)
INSTALLATION
The Water in Fuel Sensor is part of the fuel filter
bowl assembly. Refer to fuel filter installation for pro-
cedure (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY/FUEL
FILTER
/
WATER
SEPARATOR
-
INSTALLATION).
FUEL HEATER RELAY
DESCRIPTION
The fuel heater relay is located in the Integrated
Power Module (IPM). This micro-relay operates the
same as a conventional relay except the terminal ori-
entation and current capacity is different, and the
relay case is smaller.
OPERATION
The fuel heater relay is a electromechanical devise
that switches battery voltage to the fuel heater when
the ECM grounds the relay coil. The fuel heater
relay can not be repaired, and if faulty or damaged,
must be replaced.
14 - 14
FUEL DELIVERY
RG
FUEL/LIFT PUMP (Continued)
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