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Chrysler Stratus Convertible. Manual - part 21

FUEL SYSTEM

TABLE OF CONTENTS

page

FUEL DELIVERY SYSTEM. . . . . . . . . . . . . . . . . . . . 1

FUEL INJECTION SYSTEM . . . . . . . . . . . . . . . . . . 21

FUEL DELIVERY SYSTEM

TABLE OF CONTENTS

page

DESCRIPTION AND OPERATION

(ORVR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 5
QUICK-CONNECT FITTINGS . . . . . . . . . . . . . . . . . 5
ROLLOVER VALVES . . . . . . . . . . . . . . . . . . . . . . . 5
FUEL TUBES/LINES/HOSES AND CLAMPS . . . . . . 5
VEHICLE DOES NOT FILL . . . . . . . . . . . . . . . . . . . 6

SERVICE PROCEDURES

FUEL SYSTEM PRESSURE RELEASE

PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FUEL PUMP REPLACEMENT. . . . . . . . . . . . . . . . . 6
FUEL TANK DRAINING . . . . . . . . . . . . . . . . . . . . . 6

HOSES AND CLAMPS . . . . . . . . . . . . . . . . . . . . . . 7
QUICK-CONNECT FITTINGS . . . . . . . . . . . . . . . . . 7

REMOVAL AND INSTALLATION

SPECIFICATIONS

TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
FUEL TANK CAPACITY . . . . . . . . . . . . . . . . . . . . 19
FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . 19

DESCRIPTION AND OPERATION

FUEL DELIVERY SYSTEM

DESCRIPTION

The front wheel drive car uses a plastic fuel tank

located rear center of the vehicle.

The in-tank fuel pump module contains the fuel

pump and pressure regulator. The pump is serviced
as part of the fuel pump module. Refer to Fuel Pump
Module.

The fuel delivery system consists of:
• the fuel pump module containing the electric

fuel pump, fuel filter/fuel pressure regulator, fuel

gauge sending unit (fuel level sensor) and a separate
fuel filter located at bottom of pump module

• Fuel tubes/lines/hoses

• Quick-connect fittings

• Fuel injector rail

• Fuel injectors

• Fuel tank

• Fuel tank filler/vent tube assembly

• Fuel tank filler tube cap
The fuel delivery system contains a replaceable in-

line filter. The filter attaches to the frame above the
rear of the fuel tank.

FUEL SYSTEM

14 - 1

OPERATION

A returnless fuel system is used on all vehicles.

Fuel is returned through the fuel pump module and
back to the fuel tank. A separate fuel return line
from the tank to the engine is no longer used.

Relieve fuel system pressure before servicing fuel

system components. Refer to the Fuel System Pres-
sure Release Procedure and follow all Cautions and
Warnings. Most fuel system components attach to the
fuel lines with quick connect fittings. Refer to Quick
Connect Fittings in this section.

FUEL PUMP MODULE

DESCRIPTION

The fuel pump module is installed in the top of the

fuel tank (Fig. 1).

The fuel pump module contains the following:
• Electric fuel pump

• Fuel pump reservoir

• Inlet strainer

• Fuel pressure regulator

• Fuel gauge sending unit

• Fuel supply line connection
The inlet strainer, fuel pressure regulator

and fuel level sensor are the only serviceable
items. If the fuel pump or electrical wiring har-
ness requires service, replace the fuel pump
module.

ELECTRIC FUEL PUMP

DESCRIPTION

The electric fuel pump is located in and is part of

the fuel pump module. It is a positive displacement,
gerotor type, immersible pump with a permanent
magnet electric motor. The fuel pump module is sus-
pended in fuel in the fuel tank.

OPERATION

The pump draws fuel through a strainer and

pushes it through the motor to the outlet. The pump
contains a check valve. The valve, in the pump out-
let, maintains pump pressure during engine off con-
ditions. The fuel pump relay provides voltage to the
fuel pump. The fuel pump has a maximum dead-
headed pressure output of approximately 880 kPa
(130 psi). The regulator adjusts fuel system pressure
to approximately 338 kPa (49 psi).

FUEL PUMP ELECTRICAL CONTROL

Voltage to operate the electric pump is supplied

through the fuel pump relay. For an electrical opera-
tional description of the fuel pump refer to fuel Pump
Relay—PCM Output.

FUEL LEVEL SENSOR

DESCRIPTION

The level sensor is attached to the side of the fuel

pump module. The level sensor consists of a float, an
arm, and a variable resistor.

OPERATION

As the fuel level increases, the float and arm move

up. This decreases the sending unit resistance, caus-
ing the fuel gauge on the instrument panel to read
full. The fuel level sensor (fuel gauge sending unit)
sends a signal to the BCM and the BCM sends the
signal over the PCI bus circuit to the PCM to indi-
cate fuel level. The purpose of this feature is to pre-
vent a false setting of misfire and fuel system
monitor trouble codes if the fuel level is less than
approximately 15 percent of its rated capacity. It is
also used to send a signal for fuel gauge operation
via the PCI bus circuits.

FUEL TANK

DESCRIPTION

The fuel tank is constructed of a plastic material.

Its main functions are for fuel storage and for place-
ment of the fuel pump module. The tank is made
from High density Polyethylene (HDPE) material.

OPERATION

All models pass a full 360 degree rollover test

without fuel leakage. To accomplish this, fuel and
vapor flow controls are required for all fuel tank con-
nections.

All models are equipped with either one or two

rollover valves mounted into the top of the fuel tank
(or pump module).

An evaporation control system is connected to the

rollover valve(s) to reduce emissions of fuel vapors

Fig. 1 Fuel Pump Module

1 – INLET STRAINER
2 – FUEL RESERVOIR
3 – FUEL PRESSURE REGULATOR
4 – FUEL LEVEL SENSOR

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FUEL SYSTEM

DESCRIPTION AND OPERATION (Continued)

into the atmosphere. When fuel evaporates from the
fuel tank, vapors pass through vent hoses or tubes to
a charcoal canister where they are temporarily held.
When the engine is running, the vapors are drawn
into the intake manifold. Certain models are also
equipped with a self-diagnosing system using a Leak
Detection Pump (LDP). Refer to the Emission Control
System for additional information.

FUEL INJECTORS

DESCRIPTION

The injectors are positioned in the intake manifold

with the nozzle ends directly above the intake valve
port (Fig. 2).

OPERATION

The fuel injectors are electrical solenoids (Fig. 3).

The injector contains a pintle that closes off an ori-
fice at the nozzle end. When electric current is sup-
plied to the injector, the armature and needle move a
short distance against a spring, allowing fuel to flow
out the orifice. Because the fuel is under high pres-
sure, a fine spray is developed in the shape of a hol-
low cone. The spraying action atomizes the fuel,
adding it to the air entering the combustion chamber.
Fuel

injectors

are

not

interchangeable

between

engines.

FUEL PRESSURE REGULATOR

DESCRIPTION

The fuel pressure regulator contains a diaphragm,

calibrated spring and a fuel return valve. The regu-
lator is mounted in the fuel pump module.

OPERATION

The fuel system uses a nonadjustable pressure reg-

ulator

that

maintains

fuel

system

pressure

approximately 338 kPa (49 psi). The spring pushes
down on the diaphragm and closes off the fuel return
port. System fuel pressure reflects the amount of fuel
pressure required to open the return port.

The pressure regulator is a mechanical device that

is NOT controlled by the PCM or engine vacuum.

PRESSURE-VACUUM FILLER CAP

DESCRIPTION

The plastic fuel fill cap is threaded/quarter turn

onto the end of the fuel filler tube.It’s purpose is to
retain vapors and fuel in the fuel tank.

OPERATION

The loss of any fuel or vapor out of the filler tube

neck is prevented by the use of a safety filler cap.
The cap releases only under significant pressure 17
kPa (2.5 psi). The vacuum release for all gas caps is
between 2.0 and 3.0 kPa (.29 and.43 psi). The cap
must be replaced by a similar unit in order for the
system to remain effective.

WARNING: REMOVE FUEL FILLER TUBE CAP TO
RELIEVE TANK PRESSURE BEFORE REMOVING
OR REPAIRING FUEL SYSTEM COMPONENTS.

NOTE: THE

MALFUNCTION

INDICATOR

LAMP

COULD BE TURNED ON IF THE FUEL FILLER CAP
IS LOOSE OR MISSING.

Fig. 2 Fuel Injector Location—Typical

1 – FUEL RAIL
2 – INTAKE MANIFOLD
3 – FUEL INJECTORS

Fig. 3 Fuel Injector

1 – FUEL INJECTOR
2 – NOZZLE
3 – TOP (FUEL ENTRY)

FUEL SYSTEM

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DESCRIPTION AND OPERATION (Continued)

ONBOARD REFUELING VAPOR RECOVERY
(ORVR)

DESCRIPTION

ORVR System Schematic and components.

OPERATION

The emission control principle used in the ORVR

system is that the fuel flowing into the filler tube
(appx. 1” I.D.) creates an aspiration effect which
draws air into the fill tube (Fig. 4). During refueling,
the fuel tank is vented to the vapor canister to cap-
ture escaping vapors. With air flowing into the filler
tube, there are no fuel vapors escaping to the atmo-
sphere. Once the refueling vapors are captured by
the canister, the vehicle’s computer controlled purge
system draws vapor out of the canister for the engine
to burn. The vapors flow is metered by the purge

solenoid so that there is no or minimal impact on
driveability or tailpipe emissions.

As fuel starts to flow through the fill tube, it opens

the normally closed check valve and enters the fuel
tank. Vapor or air is expelled from the tank through
the control valve to the vapor canister. Vapor is
absorbed in the canister until vapor flow in the lines
stops, either following shut-off or by having the fuel
level in the tank rise high enough to close the control
valve. The control valve contains a float that rises to
seal the large diameter vent path to the canister. At
this point in the fueling of the vehicle, the tank pres-
sure increase, the check valve closes (preventing tank
fuel from spiting back at the operator), and fuel then
rises up the filler tube to shut-off the dispensing noz-
zle.

If the engine is shut-off while the On-Board diag-

nostics test is running, low level tank pressure can
be trapped in the fuel tank and fuel can not be added

Fig. 4 ORVR System Schematic

1 – FUEL CAP
2 – RECIRCULATION TUBE
3 – LIQUID SEPARATOR
4 – PURGE
5 – W/LDP
6 – BREATHER ELEMENT

7 – W/O LDP
8 – CANISTER
9 – ROLLOVER VALVE
10 – FUEL TANK
11 – CHECK VALVE
12 – CONTROL VALVE

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FUEL SYSTEM

DESCRIPTION AND OPERATION (Continued)

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