Chrysler Crossfire. Manual - part 684

Pump. The Fuel Pump has a maximum deadheaded pressure output of approximately 9.0 kPa (130 psi). The Reg-
ulator adjusts Fuel System pressure to approximately 3.7 - 4.1 bar (54 - 60 psi).

DIAGNOSIS AND TESTING

FUEL PUMP TEST

FUEL PUMP PRESSURE TEST

Use this test in conjunction with the Fuel Pump Capacity Test, Fuel Pressure Leak Down Test and Fuel Pump
Amperage Test.

The Fuel Pump contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply
line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gas-
oline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop (cold fluid contracts),
but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. When the Electric Fuel
Pump is activated, fuel pressure should immediately rise (1–2 seconds) to specification.

The Fuel System is equipped with a separate Fuel Pump mounted to the chassis along side of the Fuel Filter/
Pressure Regulator. The Fuel Filter/Pressure Regulator is not controlled by engine vacuum.

WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF.
BEFORE DISCONNECTING FUEL LINE AT FUEL RAIL, THIS PRESSURE MUST BE RELEASED. REFER TO
THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE.

1. Remove the protective cap and connect the 0–6.9

bar fuel pressure gauge (2) to the fuel rail service
test port pressure fitting (1) on the fuel rail (3). The
DRB III

Scan Tool, the 34.4 bar pressure trans-

ducer, and the transducer-to-test port adapter
may also be used in place of the fuel pressure
gauge.

2. Start and warm engine and note pressure gauge

reading. Fuel pressure should be 3.7 - 4.1 bar (54
- 60 psi) at idle.

3. If engine runs, but pressure is below 3.7 bar (54

psi), check for a kinked fuel supply line somewhere
between fuel rail (3) and fuel pump. If line is not
kinked, but specifications for either the Fuel Pump
Capacity, Fuel Pump Amperage or Fuel Pressure
Leak Down Tests were not met, replace the fuel
pump. Refer to Fuel Pump removal/installation.

4. If operating pressure is above 4.1 bar (60 psi), electric fuel pump is OK, but fuel filter/pressure regulator is defec-

tive. Replace fuel filter/pressure regulator. Refer to Fuel Filter/Pressure Regulator removal/installation.

5. Install the protective cap to the service test port pressure fitting (1) on the fuel rail.

FUEL PUMP CAPACITY TEST

Before performing this test, verify fuel pump pressure. Refer to Fuel Pump Pressure Test. Use this test in
conjunction with the Fuel Pressure Leak Down Test.

1. Release fuel system pressure. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE).

2. Disconnect fuel supply line at fuel rail.

3. Obtain the correct Fuel Line Pressure Test Adapter Tool Hose.

4. Connect the correct Fuel Line Pressure Test Adapter Tool Hose into disconnected fuel supply line. Insert other

end of Adaptor Tool Hose into a graduated container.

5. Remove the fuel tank filler cap.

6. Turn the ignition switch to the ON/RUN position.

7. A good Fuel Pump will deliver 1 liter (1.05 qt.) of fuel in a maximum of 35 seconds.

FUEL DELIVERY

14 - 17

a. If capacity is lower than specification, but Fuel Pump can be heard operating, check for a kinked/damaged

fuel supply line somewhere between fuel rail and Fuel Pump.

b. If line is not kinked/damaged, and fuel pressure is OK, but capacity is low, replace fuel filter/pressure reg-

ulator assembly. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL FILTER - REMOVAL).

c. If both fuel pressure and capacity are low, replace the Fuel Pump and the Fuel Filter/Pressure Regulator

assemblies. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL PUMP - REMOVAL)(Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/FUEL FILTER - REMOVAL)

FUEL PUMP AMPERAGE TEST

This amperage (current draw) test is to be done in conjunction with the Fuel Pump Pressure Test, Fuel Pump
Capacity Test and Fuel Pressure Leak Down Test. Before performing the amperage test, be sure the temperature of
the fuel tank is above 10° C (50° F).

The DRB III

Scan Tool along with the DRB III

Low

Current Shunt (LCS) adapter, and its test leads, will
be used to check fuel pump amperage specifications.

1. Be sure fuel tank contains fuel before starting test.

If tank is empty or near empty, amperage readings
will be incorrect.

2. Obtain LCS adapter (1).

3. Plug cable from LCS adapter (2) into DRB III

scan

tool at SET 1 receptacle.

4. Plug DRB III

into vehicle 16–way connector (data

link connector).

5. Connect (-) and (+) test cable leads into LCS

adapter receptacles (3). Use 10 amp (10A +)
receptacle and common (-) receptacles.

6. Gain access to MAIN MENU on DRB III

screen.

7. Press DVOM button on DRB III

8. Using left/right arrow keys, highlight CHANNEL 1 function on DRB III

screen.

9. Press ENTER three times.

10. Using up/down arrow keys, highlight RANGE on DRB III

screen (screen will default to 2 amp scale).

11. Press ENTER to change 2 amp scale to 10 amp scale. This step must be done to prevent damage to DRB

III

Scan Tool or LCS adapter (blown fuse).

12. Remove cover from Control Module Box and remove the fuel pump relay fuse (Refer to label on Control Module

Box cover for fuse location).

WARNING: BEFORE PROCEEDING TO NEXT STEP, NOTE THE FUEL PUMP WILL BE ACTIVATED AND SYS-
TEM PRESSURE WILL BE PRESENT. THIS WILL OCCUR AFTER CONNECTING TEST LEADS FROM LCS
ADAPTER INTO FUEL PUMP FUSE CAVITIES. THE FUEL PUMP WILL OPERATE EVEN WITH IGNITION KEY
IN OFF POSITION. BEFORE ATTACHING TEST LEADS, BE SURE ALL FUEL LINES AND FUEL SYSTEM COM-
PONENTS ARE CONNECTED.

CAUTION: To prevent possible damage to the vehicle electrical system and LCS adapter, the test leads must
be connected into fuse cavities.

13. Attach the test leads from LCS adapter into the fuel relay fuse cavities. For location of these cavities, refer to

component locator views.

14. When the LCS adapter test leads are attached to the fuel pump relay fuse cavities, the fuel pump will be

activated. Determine fuel pump amperage on DRB III

screen. Amperage should be below 9.0 amps. If amper-

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FUEL DELIVERY

age is below 9.0 amps, and specifications for the Fuel Pump Pressure, Fuel Pump Capacity and Fuel Pressure
Leak Down tests were met, the fuel pump is OK.

15. If amperage is more than 9.0 amps, replace the fuel pump assembly. The Electric Fuel Pump is serviced sep-

arately.

16. Disconnect test leads from relay fuse cavities immediately after testing.

REMOVAL

WARNING: PLACE A SHOP TOWEL AROUND THE FUEL LINES TO CATCH ANY EXCESS FUEL DURING DIS-
ASSEMBLY.

1. Disconnect the negative battery cable.

2. Raise and support the vehicle.

3. Remove the fuel pump splash shield.

4. Pinch off the fuel suction hose (6) and the fuel delivery hose (2).

5. Disconnect the hoses from the fuel pump (4).

6. Disconnect the fuel pump harness connectors (3).

7. Remove the clamp retaining screw (1) and remove the fuel pump from the vehicle.

FUEL DELIVERY

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INSTALLATION

1. Install the fuel pump into the clamp, install the

clamp retaining screw and tighten.

2. Install the fuel pump harness connectors.

3. Install both the fuel suction hose (4) and the fuel

delivery hose to the fuel pump and tighten.

4. Install the fuel pump splash shield.

5. Lower the vehicle.

6. Connect the negative battery cable.

FUEL RAIL

DESCRIPTION

The Fuel Rail is used to mount the Fuel Injectors to the engine and is itself mounted to the Intake Manifold. The
Fuel Rail supplies the necessary fuel to each individual Fuel Injector and is located above the Intake Manifold and
Fuel Injectors. The Fuel Rail is also equipped with a service port. The service port is used to connect a mechanical
fuel pressure gauge to perform pressure tests.

OPERATION

The Fuel Rail is designed to function in a semi-returnless Fuel System. The Fuel Pressure Regulator is no longer
mounted to the fuel rail. The Fuel Pressure Regulator is now located on the Fuel Pump. Refer to Fuel Filter/Fuel
Pressure Regulator in the Fuel Delivery System section of this group for information. The fuel rail is not repairable,
and must be replaced if it is damaged or malfunctioning.

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