Chrysler Stratus Convertible. Manual — part 25

(15) Remove tank from vehicle. Slide tank forward

during removal to allow fill neck to clear suspension
cross-member.

INSTALLATION

(1) Position fuel tank on transmission jack.
(2) Raise tank into position.
(3) Connect vapor line to tee to rollover valve.
(4) Install EVAP hoses and lines.
(5) Connect fuel pump electrical connector.
(6) Install pump module harness grommet into

body.

(7) Connect chassis fuel tube to fuel filter. Refer to

Quick Connect Fittings in this section.

(8) Connect fuel fill tube to tank inlet. Tighten

hose clamp to 3.5 N·m (31 in. lbs.) torque.

(9) Position fuel filter and fuel tank straps. Install

the front bolts first and then the rear bolts. Tighten
fuel tank strap bolts to 23 N·m (250 in. lbs.) torque.
Remove transmission jack. Ensure straps are not
twisted or bent.

(10) Lower vehicle.
(11) Connect fuel pump module connector, inside of

vehicle. Install rear seat cushion.

(12) Fill fuel tank, install filler cap, and connect

battery cable.

CAUTION: When using the ASD Fuel System Test,
the ASD relay remains energized for several min-
utes, or until the test is stopped, or until the igni-
tion switch is turned to the Off position.

(13) Use the DRB scan tool ASD Fuel System Test

to pressurize the fuel system. Check for leaks.

FUEL FILLER NECK

REMOVAL

(1) Loosen fuel filler tube cap.
(2) Remove fuel filler neck screws (Fig. 31).
(3) Disconnect Ground strap from body.
(4) Disconnect fuel filler tube hose from fuel tank

neck. Remove fuel filler tube assembly.

INSTALLATION

(1) Install fuel filler tube. Connect fuel filler tube

hose to fuel tank neck.

(2) Install fuel filler neck screws (Fig. 31).
(3) Install fuel filler tube cap.

ACCELERATOR PEDAL

REMOVAL

(1) Remove the throttle cable from the throttle

body cam as described in Throttle Cable of this sec-
tion.

(2) Reach behind the top of the pedal shaft and

push the retainer toward rear of vehicle (Fig. 32). It
may be necessary to squeeze retainer ears together
on dash side of pedal shaft.

(3) Lift cable up through slot in top of pedal shaft.

(4) Remove nuts from accelerator pedal assembly

studs. Remove assembly from vehicle.

Fig. 31 Fuel Filler Neck Removal/Installation

1 – FILLER CAP
2 – FILLER NECK

Fig. 32 Accelerator Pedal and Throttle Cable

1 – CABLE
2 – PEDAL SHAFT
3 – DASH PANEL

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FUEL SYSTEM

14 - 17

REMOVAL AND INSTALLATION (Continued)

INSTALLATION

(1) Position accelerator pedal assembly on dash

panel. Install retaining nuts. Tighten retaining nuts
to 12 N·m (105 in. lbs.) torque.

(2) Place cable through slot in top of pedal shaft.
(3) While holding pedal lever, Push retainer clip

forward in vehicle engaging it into the pedal lever.

(4) Hold the throttle body lever in the wide open

position and install the throttle cable.

THROTTLE CABLE—2.0L

REMOVAL

(1) Working from the engine compartment, remove

the throttle cable from the throttle body lever (Fig.
33) and (Fig. 34).

(2) Compress the retaining tabs on the cable and

slide cable out of bracket (Fig. 34).

(3) From inside vehicle, reach behind the top of

the pedal shaft and push the retainer toward rear of
vehicle. It may be necessary to squeeze retainer ears
together on dash side of pedal shaft.

(4) Lift cable up through slot in top of pedal shaft.
(5) Remove throttle cable clip attached at grommet

in front of dash panel.

(6) From the engine compartment, pull the throttle

cable and grommet out of the dash panel.

INSTALLATION

(1) From the engine compartment, push the cable

end fitting and grommet into the dash panel.

(2) Install throttle cable clip.
(3) Install cable housing (throttle body end) into

the cable mounting bracket on the engine.

(4) Place cable through slot in top of pedal shaft.

(5) While holding the pedal lever, push retainer

clip forward in vehicle engaging it into the pedal
lever.

(6) From the engine compartment, rotate the

throttle lever forward to the wide open position and
install cable clasp (Fig. 34).

Fig. 33 Throttle Cable Attachment to Throttle Body

1 – SPEED CONTROL CABLE
2 – THROTTLE CABLE
3 – THROTTLE LEVER

Fig. 34 Disconnecting Throttle Cable

1 – TABS
2 – CABLE CLASP

Fig. 35 Cable Routing 2.0L

1 – THROTTLE CABLE
2 – HEATER HOSES

14 - 18

FUEL SYSTEM

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REMOVAL AND INSTALLATION (Continued)

SPECIFICATIONS

TORQUE

DESCRIPTION

TORQUE

Accelerator Pedal to Dash Nuts . . . . . . . . . 12 N·m

(105 in. lbs.)

Fuel Filter Mounting Screw . . 12 N·m (110 in. lbs.)
Fuel Pump Module Locknut . . 74.5 N·m (55 ft. lbs.)
Fuel Tank strap Bolts . . . . . 28.2 N·m (250 in. lbs.)
Fuel Rail Bolts—2.0L . . . . . . 22.5 N·m (200 in. lbs.)
Ignition Coil Mounting Bolts . 12 N·m (105 in. lbs.)

FUEL TANK CAPACITY

FUEL REQUIREMENTS

Your engine is designed to meet all emissions reg-

ulations and provide excellent fuel economy and per-
formance when using high quality unleaded gasoline
having an octane rating of 87. The use of premium
gasoline is not recommended. The use of premium
gasoline will provide no benefit over high quality reg-
ular gasoline, and in some circumstances may result
in poorer performance.

Light spark knock at low engine speeds is not

harmful to your engine. However, continued heavy
spark knock at high speeds can cause damage and
immediate service is required. Engine damage result-
ing from operation with a heavy spark knock may
not be covered by the new vehicle warranty.

Poor quality gasoline can cause problems such as

hard starting, stalling and hesitations. If you experi-
ence these symptoms, try another brand of gasoline
before considering service for the vehicle.

Over 40 auto manufacturers world-wide have

issued and endorsed consistent gasoline specifications
(the Worldwide Fuel Charter, WWFC) to define fuel
properties necessary to deliver enhanced emissions,
performance and durability for your vehicle. We rec-
ommend the use of gasolines that meet the WWFC
specifications if they are available.

REFORMULATED GASOLINE

Many areas of the country require the use of

cleaner burning gasoline referred to as “reformulat-
ed” gasoline. Reformulated gasoline contain oxygen-
ates, and are specifically blended to reduce vehicle
emissions and improve air quality.

We strongly supports the use of reformulated gas-

oline. Properly blended reformulated gasoline will
provide excellent performance and durability for the
engine and fuel system components.

GASOLINE/OXYGENATE BLENDS

Some fuel suppliers blend unleaded gasoline with

oxygenates such as 10% ethanol, MTBE, and ETBE.
Oxygenates are required in some areas of the country
during the winter months to reduce carbon monoxide
emissions. Fuels blended with these oxygenates may
be used in your vehicle.

CAUTION: DO NOT use gasoline containing METH-
ANOL. Gasoline containing methanol may damage
critical fuel system components.

MMT IN GASOLINE

MMT is a manganese-containing metallic additive

that is blended into some gasoline to increase octane.
Gasoline blended with MMT provide no performance
advantage beyond gasoline of the same octane num-
ber without MMT. Gasoline blended with MMT
reduce spark plug life and reduce emission system
performance in some vehicles. We recommend that
gasolines free of MMT be used in your vehicle. The
MMT content of gasoline may not be indicated on the
gasoline pump; therefore, you should ask your gaso-
line retailer whether or not his/her gasoline contains
MMT.

It is even more important to look for gasoline with-

out MMT in Canada because MMT can be used at
levels higher than allowed in the United States.
MMT is prohibited in Federal and California refor-
mulated gasoline.

SULFUR IN GASOLINE

If you live in the northeast United States, your

vehicle may have been designed to meet California
low emission standards with Cleaner-Burning Cali-
fornia reformulated gasoline with low sulfur. If such
fuels are not available in states adopting California
emission standards, your vehicles will operate satis-
factorily on fuels meeting federal specifications, but
emission

control

system

performance

may

be

adversely affected. Gasoline sold outside of California
is permitted to have higher sulfur levels which may
affect the performance of the vehicle’s catalytic con-
verter. This may cause the Malfunction Indicator
Lamp (MIL), Check Engine or Service Engine Soon
light to illuminate. We recommend that you try a dif-
ferent brand of unleaded gasoline having lower sulfur
to determine if the problem is fuel related prior to
returning your vehicle to an authorized dealer for
service.

Vehicle

Liters

U.S. Gallons

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60

16

Nominal refill capacities are shown. A variation may
be observed from vehicle to vehicle due to
manufacturing tolerance and refill procedure.

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FUEL SYSTEM

14 - 19

CAUTION: If the Malfunction Indicator Lamp (MIL),
Check Engine or Service Engine Soon light is flash-
ing, immediate service is required; see on-board
diagnostics system section.

MATERIALS ADDED TO FUEL

All gasoline sold in the United States and Canada

are required to contain effective detergent additives.
Use of additional detergents or other additives is not
needed under normal conditions.

FUEL SYSTEM CAUTIONS

CAUTION: Follow these guidelines to maintain your
vehicle’s performance:

• The use of leaded gas is prohibited by Federal

law. Using leaded gasoline can impair engine perfor-
mance, damage the emission control system, and
could result in loss of warranty coverage.

• An out-of-tune engine, or certain fuel or ignition

malfunctions, can cause the catalytic converter to

overheat. If you notice a pungent burning odor or
some light smoke, your engine may be out of tune or
malfunctioning and may require immediate service.
Contact your dealer for service assistance.

• When pulling a heavy load or driving a fully

loaded vehicle when the humidity is low and the tem-
perature is high, use a premium unleaded fuel to
help prevent spark knock. If spark knock persists,
lighten the load, or engine piston damage may result.

• The use of fuel additives which are now being

sold as octane enhancers is not recommended. Most
of these products contain high concentrations of
methanol. Fuel system damage or vehicle perfor-
mance problems resulting from the use of such fuels
or additives is not the responsibility of Daimler-
Chrysler Corporation and may not be covered under
the new vehicle warranty.

NOTE: Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.

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FUEL SYSTEM

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SPECIFICATIONS (Continued)