Fuel Delivery - Chrysler PT Cruiser Service & Repair Manual

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FUEL DELIVERY

FUEL DELIVERY
DESCRIPTION
The front wheel drive car uses a plastic fuel tank
located rear center of the vehicle.
The Fuel Delivery System consists of: the following
items:
• Electric fuel pump module
• Fuel filter
• Tubes/lines/hoses
• Fuel injectors
The in-tank fuel pump module contains the fuel
pump. The pump is serviced as part of the fuel pump
module. Refer to Fuel Pump Module.
The fuel filter is not serviceable, it is mounted on
the inside of the fuel tank in the fuel pump module.
OPERATION
The fuel system provides fuel pressure by an
in-tank pump module. The PCM controls the opera-
tion of the fuel system by providing battery voltage
to the fuel pump through the fuel pump relay. The
PCM requires only three inputs and a good ground to
operate the fuel pump relay. The three inputs are:
• Ignition voltage
• Crankshaft Position (CKP) sensor
• Camshaft Position (CMP) sensor
DIAGNOSIS AND TESTING - FUEL DELIVERY
SYSTEM
(Refer to Appropriate Diagnostic Information)
STANDARD PROCEDURE
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE PROCEDURE
(1) Remove Fuel Pump relay from Power Distribu-
tion Center (PDC). For location of relay, refer to label
on underside of PDC cover.
(2) Start and run engine until it stalls.
(3) Attempt restarting engine until it will no
longer run.
(4) Turn ignition key to OFF position.
(5) Return fuel pump relay to PDC.
(6) One or more Diagnostic Trouble Codes (DTC's)
may have been stored in PCM memory due to fuel
pump relay removal. The DRB III scan tool must be
used to erase a DTC.
STANDARD PROCEDURE - DRAINING FUEL
TANK
Two different procedures may be used to drain fuel
tank (lowering tank or using DRB scan tool).
The quickest draining procedure involves lowering
the fuel tank.
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE.
As an alternative procedure, the electric fuel pump
may be activated allowing tank to be drained at fuel
rail connection. Refer to DRBIII
pump activation procedures. Before disconnecting
fuel line at fuel rail, release fuel pressure. Refer to
the Fuel System Pressure Release Procedure in this
group for procedures. Disconnect the fuel line at the
fuel rail and remove the plastic retainer from the
fuel rail. Take plastic retainer and install it back into
the fuel line from body. Attach end of special test
hose tool number 8978 at fuel line connection from
the body line. Position opposite end of this hose tool
to an approved gasoline draining station. Activate
fuel pump and drain tank until empty. When done
remove the special test hose tool number 8978 from
the body line. Remove the plastic retainer from the
special test hose tool number 8978 and reinstall it
into the fuel line from the body. Install the fuel line
to the fuel rail.
If electric fuel pump is not operating, tank must be
lowered for fuel draining. Refer to following proce-
dures.
(1) Remove fuel filler cap.
(2) Perform the Fuel System Pressure Release pro-
cedure.
(3) Disconnect negative cable from battery.
(4) Raise vehicle and support.
(5) Certain models are equipped with a separate
grounding wire (strap) connecting the fuel fill tube
assembly to the body. Disconnect wire by removing
screw.
(6) Open fuel fill door and remove screws mount-
ing fuel filler tube assembly to body. Do not discon-
nect rubber fuel fill or vent hoses from tank at this
time.
(7) Place a transmission jack under center of fuel
tank. Apply a slight amount of pressure to fuel tank
with transmission jack.
(8) Remove fuel tank mounting strap nuts from
mounting strap studs.
(9) Lower the tank just enough so that the
filler tube fitting is the highest point of the fuel
tank.
(10) Remove filler tube from fuel tank. Tank will
be drained through this fitting.
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
PT
scan tool for fuel