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FUEL SYSTEM
CONTENTS
page page
FUEL DELIVERY SYSTEM. . . . . . . . . . . . . . . . . 3FUEL INJECTION SYSTEM. . . . . . . . . . . . . . . . 26GENERAL INFORMATION. . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . 1GASOLINE/OXYGENATE BLENDS . . . . . . . . . . . 1INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION
INTRODUCTION
Throughout this group, references may be made toa particular vehicle by letter or number designation.A chart showing the breakdown of these designationsis included in the Introduction Section at the front of this service manual.The Evaporation Control System, is also consideredpart of the fuel system. The system reduces the emis-sion of fuel vapor into the atmosphere.The description and function of the EvaporationControl System is found in Group 25 of this manual.
FUEL REQUIREMENTS
Your vehicle was designed to meet all emission reg-ulations and provide excellent fuel economy whenusing high quality unleaded gasoline.Use unleaded gasolines having a minimum postedoctane of 87.If your vehicle develops occasional light spark knock (ping) at low engine speeds this is not harm-ful. However; continued heavy knock at high speedscan cause damage and should be reported to yourdealer immediately. Engine damage as a result of heavy knock operation may not be covered by thenew vehicle warranty.In addition to using unleaded gasoline with theproper octane rating, those that contain detergents,corrosion and stability additives are recommended.Using gasolines that have these additives will helpimprove fuel economy, reduce emissions, and main-tain vehicle performance.Poor quality gasoline can cause problems such ashard starting, stalling, and stumble. If you experi-ence these problems, try another brand of gasolinebefore considering service for the vehicle.
GASOLINE/OXYGENATE BLENDS
Some fuel suppliers blend unleaded gasoline withmaterials that contain oxygen such as alcohol, MTBE(Methyl Tertiary Butyl Ether) and ETBE (Ethyl Ter-tiary Butyl Ether). Oxygenates are required in someareas of the country during winter months to reducecarbon monoxide emissions. The type and amount of oxygenate used in the blend is important.The following are generally used in gasolineblends:
Ethanol
- (Ethyl or Grain Alcohol) properlyblended, is used as a mixture of 10 percent ethanoland 90 percent gasoline. Gasoline blended with etha-nol may be used in your vehicle.
MTBE/ETBE
- Gasoline and MTBE (Methyl Ter-tiary Butyl Ether) blends are a mixture of unleadedgasoline and up to 15 percent MTBE. Gasoline andETBE (Ethyl Tertiary Butyl Ether) are blends of gas-oline and up to 17 percent ETBE. Gasoline blendedwith MTBE or ETBE may be used in your vehicle.
Methanol
- Methanol (Methyl or Wood Alcohol) isused in a variety of concentrations blended withunleaded gasoline. You may encounter fuels contain-ing 3 percent or more methanol along with otheralcohols called cosolvents.
DO NOT USE GASOLINES CONTAININGMETHANOL.
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FUEL SYSTEM 14 - 1
 
Use of methanol/gasoline blends may result instarting and driveability problems and damage criti-cal fuel system components.Problems that are the result of using methanol/ gasoline blends are not the responsibility of ChryslerCorporation and may not be covered by the vehiclewarranty.
Reformulated Gasoline
Many areas of the country are requiring the use of cleaner-burning fuel referred to as
ReformulatedGasoline
. Reformulated gasolines are speciallyblended to reduce vehicle emissions and improve airquality.Chrysler Corporation strongly supports the use of reformulated gasolines whenever available. Althoughyour vehicle was designed to provide optimum perfor-mance and lowest emissions operating on high qual-ity unleaded gasoline, it will perform equally welland produce even lower emissions when operating onreformulated gasoline.
Materials Added to Fuel
Indiscriminate use of fuel system cleaning agentsshould be avoided. Many of these materials intendedfor gum and varnish removal may contain active sol-vents of similar ingredients that can be harmful tofuel system gasket and diaphragm materials.
14 - 2 FUEL SYSTEM
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GENERAL INFORMATION (Continued)
 
FUEL DELIVERY SYSTEM
INDEX
page page
DESCRIPTION AND OPERATION
FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . 3FUEL FILTER/FUEL PRESSURE REGULATOR . . 4FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . . 4FUEL INJECTORS—4.0L ENGINE . . . . . . . . . . . 5FUEL INJECTORS—5.2L/5.9L ENGINES. . . . . . 5FUEL PUMP MODULE . . . . . . . . . . . . . . . . . . . . 4FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4FUEL RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6FUEL TANK FILLER TUBE CAP . . . . . . . . . . . . . 6FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5QUICK-CONNECT FITTINGS . . . . . . . . . . . . . . . 6ROLLOVER VALVE(S) . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS AND TESTING
FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . 10FUEL INJECTOR TEST . . . . . . . . . . . . . . . . . . 10FUEL PRESSURE LEAK DOWN TEST. . . . . . . . 9FUEL PUMP CAPACITY TEST. . . . . . . . . . . . . . 9FUEL PUMP PRESSURE TEST—5.2L/5.9LENGINES WITH PRESSURE TEST PORT. . . . 7FUEL PUMP PRESSURE TEST—5.2L/5.9LENGINES WITHOUT PRESSURETEST PORT. . . . . . . . . . . . . . . . . . . . . . . . . . 8FUEL PUMP PRESSURE TEST–4.0L ENGINE. . 7
SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASEPROCEDURE—WITHOUT PRESSURE TESTPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11FUEL SYSTEM PRESSURE RELEASEPROCEDURE–WITH PRESSURE TESTPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10FUEL TUBES/LINES/HOSES AND CLAMPS . . . 11QUICK-CONNECT FITTINGS . . . . . . . . . . . . . . 12
REMOVAL AND INSTALLATION
ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . 23FUEL FILTER/FUEL PRESSURE REGULATOR . 16FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . 18FUEL INJECTOR RAIL—4.0L ENGINE . . . . . . . 20FUEL INJECTOR RAIL—5.2L/5.9L ENGINES . . 18FUEL INJECTOR(S) . . . . . . . . . . . . . . . . . . . . . 20FUEL PUMP INLET FILTER . . . . . . . . . . . . . . . 17FUEL PUMP MODULE . . . . . . . . . . . . . . . . . . . 17FUEL TANK FILLER TUBE CAP. . . . . . . . . . . . 22FUEL TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . 21THROTTLE CABLE. . . . . . . . . . . . . . . . . . . . . 23
SPECIFICATIONS
FUEL SYSTEM PRESSURE. . . . . . . . . . . . . . . 24FUEL TANK CAPACITY. . . . . . . . . . . . . . . . . . 24TORQUE CHART. . . . . . . . . . . . . . . . . . . . . . . 25VECI LABEL. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DESCRIPTION AND OPERATION
FUEL DELIVERY SYSTEM
The fuel delivery system consists of:
•
the fuel pump module containing the electricfuel pump, fuel filter/fuel pressure regulator, fuelgauge sending unit (fuel level sensor) and a separatefuel 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
•
accelerator pedal
•
throttle cableFuel is returned through the fuel pump moduleand back into the fuel tank through the fuel filter/ fuel pressure regulator. A separate fuel return linefrom the engine to the tank is not used.The fuel tank assembly consists of: the fuel tank,fuel pump module assembly, fuel pump module lock-nut/gasket, and rollover valve (refer to Group 25,Emission Control System for rollover valve informa-tion).A fuel filler/vent tube assembly consisting of apressure-vacuum filler cap is used.Also to be considered part of the fuel system is theevaporation control system containing the pressurerelief/rollover valve. This is designed to reduce theemission of fuel vapors into the atmosphere. Thedescription and function of the Evaporative ControlSystem is found in Group 25, Emission Control Sys-tems.Both fuel filters (at bottom of fuel pump moduleand within fuel pressure regulator) are designed forextended service. They do not require normal sched-uled maintenance. Filters should only be replaced if a diagnostic procedure indicates to do so.
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