CHRYSLER TOWN AND COUNTRY 2002 Service Manual

FUEL DELIVERY
TABLE OF CONTENTS
page page
FUEL RAIL
DESCRIPTION..........................4
OPERATION............................4
REMOVAL - FUEL RAIL...................4
INSTALLATION - FUEL RAIL................5
FUEL FILTER / WATER SEPARATOR
DESCRIPTION..........................5
OPERATION............................5
FUEL LINES
DESCRIPTION
DESCRIPTION........................6
DESCRIPTION - HIGH PRESSURE FUEL
LINES...............................6OPERATION - HIGH PRESSURE FUEL LINES . . 6
DIAGNOSIS AND TESTING - HIGH
PRESSURE FUEL LINES.................6
FUEL TRANSFER PUMP
DESCRIPTION..........................7
OPERATION............................7
FUEL INJECTION PUMP
DESCRIPTION..........................7
REMOVAL.............................7
INSTALLATION..........................9
WATER IN FUEL SENSOR
DESCRIPTION.........................10
OPERATION...........................10
FUEL RAIL
DESCRIPTION
The fuel rail is mounted to the cylinder head cover/
intake manifold (Fig. 1).
OPERATION
The fuel rail stores the fuel for the injectors at
high pressure. At the same time, the pressure oscil-
lations which are generated due to the high-pressure
pump delivery and the injection of fuel are dampened
by the rail volume.
The fuel rail is common to all cylinders, hence it's
name ªcommon railº. Even when large quantities of
fuel are extracted, the fuel rail maintains a constant
inner pressure. This ensures that the injection pres-
sure remains constant from the moment the injector
opens.
REMOVAL - FUEL RAIL
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Disconnect fuel injector high pressure lines.
(4) Disconnect fuel rail supply line. (Fig. 2)
(5) Disconnect fuel rail return line. (Fig. 2)
(6) Disconnect fuel rail high pressure sensor con-
nector. (Fig. 2)
(7) Remove engine electrical harness retainers
from the fuel rail retaining bolts/studs. (Fig. 2)
(8) Remove fuel rail retaining bolts and remove
fuel rail (Fig. 2).Fig. 1 ENGINE COMPONENT LOCATIONS
1 - FUEL INJECTOR RETURN LINE
2 - FUEL INJECTOR HIGH PRESSURE LINE
3 - OIL SEPARATOR
4 - FUEL INJECTOR
5 - CAMSHAFT POSITION SENSOR
6 - BOOST PRESSURE/INTAKE AIR TEMPERATURE SENSOR
7 - EGR SOLENOID
8 - FUEL PRESSURE SENSOR
9 - CYLINDER HEAD COVER/INTAKE MANIFOLD
10 - FUEL RAIL
14a - 4 FUEL DELIVERYRG
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INSTALLATION - FUEL RAIL
(1) Install fuel rail to intake manifold/cylinder
head cover (Fig. 2). Torque retaining bolts to
27.5N´m.
(2) Install engine electrical harness retainers from
the fuel rail retaining bolts/studs. (Fig. 2)
(3) Connect fuel rail high pressure sensor electri-
cal connector. (Fig. 2)
(4) Connect fuel rail return line. (Fig. 2)
(5) Connect fuel rail supply line. (Fig. 2)
(6) Connect fuel injector high pressure lines. (Fig.
2)
(7) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(8) Connect negative battery cable.
FUEL FILTER / WATER
SEPARATOR
DESCRIPTION
The fuel filter/water separator assembly is located
under the vehicle in front of the rear axle assembly
(Fig. 3). The assembly also includes the fuel heater
and Water-In-Fuel (WIF) sensor.
OPERATION
The fuel filter/water separator protects the fuel
injection pump by removing water and contaminants
from the fuel. The construction of the filter/separator
allows fuel to pass through it, but helps prevent
moisture (water) from doing so. Moisture collects at
the bottom of the canister.
Fig. 2 FUEL RAIL COMPONENTS
1 - FUEL INJECTOR RETURN LINE
2 - FUEL INJECTOR HIGH PRESSURE LINE
3 - OIL SEPARATOR
4 - FUEL INJECTOR
5 - CAMSHAFT POSITION SENSOR
6 - BOOST PRESSURE/INTAKE AIR TEMPERATURE SENSOR
7 - EGR SOLENOID
8 - FUEL PRESSURE SENSOR
9 - CYLINDER HEAD COVER/INTAKE MANIFOLD
10 - FUEL RAIL
Fig. 3 FUEL FILTER/WATER SEPARATOR
1 - LIFT PUMP RETAINING BOLTS
2 - LIFT PUMP
3 - FUEL FILTER/WATER SEPARATOR HOUSING
4 - FUEL HEATER
5 - CHECK BALL
6 - O-RING
7 - FLOW DIVERTER
8 - FUEL FILTER
9 - O-RING
10 - FUEL FILTER BOWL ASSEMBLY
RGFUEL DELIVERY14a-5
FUEL RAIL (Continued)
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Refer to the maintenance schedules for the recom-
mended fuel filter replacement intervals.
For draining of water from canister, refer to Fuel
Filter/Water Separator Removal/Installation section.
A Water-In-Fuel (WIF) sensor is part of the fuel fil-
ter cap. Refer to Water-In-Fuel Sensor Description/
Operation.
The fuel heater is installed into the filter/separator
housing above the fuel filter. Refer to Fuel Heater
Description/Operation.
FUEL LINES
DESCRIPTION
DESCRIPTION
All fuel lines up to the fuel injection pump are con-
sidered low-pressure. This includes the fuel lines
from: the fuel tank to the fuel transfer pump, and
the fuel transfer pump to the fuel injection pump.
The fuel return lines and the fuel drain lines are also
considered low-pressure lines. High-pressure lines
are used between the fuel injection pump and the
fuel injectors. Also refer to High-Pressure Fuel Lines
Description/Operation.
DESCRIPTION - HIGH PRESSURE FUEL LINES
The high-pressure fuel lines are the 4 lines located
between the fuel injection pump and the fuel injec-
torsctor tubes. All other fuel lines are considered low-
pressure lines.
OPERATION - HIGH PRESSURE FUEL LINES
CAUTION: The high-pressure fuel lines cannot con-
tact each other or other components. Do not
attempt to weld high-pressure fuel lines or to repair
lines that are damaged. If lines are ever kinked or
bent, they must be replaced. Use only the recom-
mended lines when replacement of high-pressure
fuel line is necessary.
High-pressure fuel lines deliver fuel under
extremely high pressure from the injection pump to
the fuel injectors. The lines expand and contract from
the high-pressure fuel pulses generated during the
injection process. All high-pressure fuel lines are of
the same length and inside diameter. Correct high-
pressure fuel line usage and installation is critical to
smooth engine operation.
WARNING: USE EXTREME CAUTION WHEN
INSPECTING FOR HIGH-PRESSURE FUEL LEAKS.
INSPECT FOR HIGH-PRESSURE FUEL LEAKS WITH
A SHEET OF CARDBOARD. HIGH FUEL INJECTIONPRESSURE CAN CAUSE PERSONAL INJURY IF
CONTACT IS MADE WITH THE SKIN.
DIAGNOSIS AND TESTING - HIGH PRESSURE
FUEL LINES
High-pressure fuel line leaks can cause starting
problems and poor engine performance.
WARNING: DUE TO EXTREME FUEL PRESSURES,
USE EXTREME CAUTION WHEN INSPECTING FOR
HIGH-PRESSURE FUEL LEAKS. DO NOT GET YOUR
HAND NEAR A SUSPECTED LEAK. INSPECT FOR
HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF
CARDBOARD. HIGH FUEL INJECTION PRESSURE
CAN CAUSE PERSONAL INJURY IF CONTACT IS
MADE WITH THE SKIN.
Start the engine. Move the cardboard over the
high-pressure fuel lines and check for fuel spray onto
the cardboard (Fig. 4). If a high-pressure line connec-
tion is leaking, bleed the system and tighten the con-
nection. Refer to the Air Bleed Procedure in this
group for procedures. Replace damaged, restricted or
leaking high-pressure fuel lines with the correct
replacement line.
Fig. 4 Typical Test for Leaks with Cardboard
1 - HIGH-PRESSURE LINE
2 - CARDBOARD
3 - FITTING
14a - 6 FUEL DELIVERYRG
FUEL FILTER / WATER SEPARATOR (Continued)
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CAUTION: The high-pressure fuel lines cannot con-
tact each other or other components. Do not
attempt to weld high-pressure fuel lines or to repair
lines that are damaged. Only use the recommended
lines when replacement of high-pressure fuel line is
necessary.
FUEL TRANSFER PUMP
DESCRIPTION
The fuel transfer pump (fuel lift pump) is located
under the vehicle in front of the rear axle assembly
(Fig. 5). The 12±volt electric vane-type pump is oper-
ated and controlled by the Engine Control Module
(ECM).
OPERATION
The purpose of the fuel transfer pump is to supply
(transfer) a low-pressure fuel source:fromthe fuel
tank,throughthe fuel filter/water separator andto
the fuel injection pump. Here, the low-pressure is
raised to a high-pressure by the fuel injection pump
for operation of the high-pressure fuel injectors.
The fuel transfer pump is controlled by the Engine
Control Module(ECM). The ECM turns the fuel
transfer pump on for 30 seconds when the ignition
ket is turned ªONº.
With the ignition ªONº and fuel tranfer pump run-
ning, the low-pressure fuel pressure should be 13-17
psi.
FUEL INJECTION PUMP
DESCRIPTION
A radial-piston pump is used as the high pressure
pump for fuel pressure generation (Fig. 6).
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL)
(3) Remove air cleaner housing assembly.
(4) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(5) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
Fig. 5 FUEL TRANSFER(LIFT) PUMP LOCATION
1 - LIFT PUMP RETAINING BOLTS
2 - LIFT PUMP
3 - FUEL FILTER/WATER SEPARATOR HOUSING
4 - FUEL HEATER
5 - CHECK BALL
6 - O-RING
7 - FLOW DIVERTER
8 - FUEL FILTER
9 - O-RING
10 - FUEL FILTER BOWL ASSEMBLY
Fig. 6 FUEL INJECTION PUMP
1 - FUEL INJECTION PUMP
2 - INJECTION PUMP PRESSURE SOLENOID
RGFUEL DELIVERY14a-7
FUEL LINES (Continued)
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(6) Support engine and remove right engine mount
assembly.
(7) Remove outer timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(8) Using special tool VM.1055, remove injection
pump sprocket retaining nut (Fig. 7).
NOTE: The use of special tool VM.1067 will allow
you to remove the injection pump without removing
the timing belt from the engine. This will allow you
to remove and install the injection pump without
altering injection pump timing.(9) Install feet from VM.1067 in injection pump
sprocket as shown (Fig. 8).
(10) Install inner flange of special tool VM.1067 on
injection pump sprocket as shown (Fig. 9). Secure
flange to feet in injection pump sprocket with allen
bolts supplied with tool.
(11) Screw injection pump sprocket holding plate
assembly into flange of VM.1067 (Fig. 10) Using LHD
threaded bolt supplied, secure holding plate assembly
to timing belt inner cover.
Fig. 7 INJECTION PUMP SPROCKET RETAINING
NUT REMOVAL/INSTALLATION
1 - IDLER PULLEY
2 - TIMING BELT
3 - VM.1055
4 - INJECTION PUMP SPROCKET
Fig. 8 VM.1067 FEET INSTALLATION
1 - OUTER TIMING BELT SEALING SURFACE
2 - TIMING BELT
3 - TIMING BELT SPROCKET
4 - FEET FOR SPECIAL TOOL VM.1067
5 - INNER TIMING BELT COVER
14a - 8 FUEL DELIVERYRG
FUEL INJECTION PUMP (Continued)
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(12) Remove generator (Fig. 11). (Refer to 8 -
ELECTRICAL/CHARGING/GENERATOR -
REMOVAL)
(13) Disconnect fuel supply and return lines at
injection pump (Fig. 11)
(14) Disconnect fuel pressure solenoid electrical
connector at injection pump (Fig. 11)
(15) Remove injection pump retaining nuts.
(16) While holding injection pump, tighten bolt in
center of injection pump holding plate (Fig. 10).This
will push the injection pump out of the injection
pump sprocket.
INSTALLATION
(1) Loosen bolt in center of injection pump holding
plate and slide injection pump through the accessory
bracket into the injection pump sprocket.
(2) Install injection pump retaining nuts (Fig. 11).
Torque nuts to 27.5N´m.
(3) Unscrew injection pump holding plate (part of
VM.1067) from inner timing belt cover and remove
(Fig. 10).
(4) Install injection pump sprocket retaining nut to
hold sprocket in place.
(5) Remove flange and feet (both part of VM.1067)
from injection pump sprocket (Fig. 9) (Fig. 8).
Fig. 9 VM.1067 INSTALLATION
1 - TIMING BELT
2 - INJECTION PUMP SPROCKET
3 - FLANGE OF VM.1067
4 - INNER TIMING BELT COVER
Fig. 10 INJECTION PUMP/GEAR REMOVAL USING
VM.1067
1 - TIMING BELT
2 - INNER TIMING BELT COVER
3 - INJECTION PUMP SPROCKET HOLDING PLATE ASSEMBLY
PART OF VM.1067
4 - INJECTION PUMP SPROCKET
RGFUEL DELIVERY14a-9
FUEL INJECTION PUMP (Continued)
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(6) Using special tool VM.1055 (Fig. 7), torque
injection pump sprocket retaining nut to 88.3N´m.
(7) Connect fuel pressure solenoid electrical con-
nector (Fig. 11).
(8) Connect fuel supply and return lines at injec-
tion pump (Fig. 11).
(9) Install generator (Fig. 11)(Refer to 8 - ELEC-
TRICAL/CHARGING/GENERATOR - INSTALLA-
TION).(10) Install outer timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(11) Install right engine mount assembly.
(12) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(13) Install power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(14) Install air cleaner housing assembly.
(15) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(16) Connect negative battery cable.
WATER IN FUEL SENSOR
DESCRIPTION
The WIF sensor is located in the bowl assembly of
the fuel filter/water separator.
OPERATION
The sensor sends an input to the Engine Control
Module (ECM) when it senses water in the fuel filter/
water separator. As the water level in the filter/sep-
arator increases, the resistance across the WIF
sensor decreases. This decrease in resistance is sent
as a signal to the ECM and compared to a high
water standard value. Once the value reaches 30 to
40 kilohms, the ECM will activate the water-in-fuel
warning lamp through CCD bus circuits. This all
takes place when the ignition key is initially put in
the ON position. The ECM continues to monitor the
input at the end of the intake manifold air heater
post-heat cycle.
Fig. 11 FUEL INJECTION PUMP LOCATION
1 - CYLINDER HEAD COVER/INTAKE MANIFOLD
2 - INJECTION PUMP
3 - FUEL PRESSURE SOLENOID
4 - ACCESSORY MOUNTING BRACKET
5 - GENERATOR
14a - 10 FUEL DELIVERYRG
FUEL INJECTION PUMP (Continued)
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FUEL INJECTION
TABLE OF CONTENTS
page page
FUEL INJECTOR
DESCRIPTION
FUEL INJECTOR......................11
OPERATION...........................11
REMOVAL.............................12
INSTALLATION.........................13
ACCELERATOR PEDAL POSITION SENSOR
DESCRIPTION.........................13
OPERATION...........................13
REMOVAL
REMOVAL - PEDAL POSITION SENSOR
(LHD)...............................14
REMOVAL - PEDAL POSITION SENSOR
(RHD)..............................14
INSTALLATION
INSTALLATION - PEDAL POSITION SENSOR
(LHD)...............................14
INSTALLATION - PEDAL POSITION SENSOR
(RHD)..............................14BOOST PRESSURE SENSOR
DESCRIPTION.........................14
OPERATION...........................14
DIAGNOSIS AND TESTING - BOOST
PRESSURE/INTAKE AIR TEMPERATURE
SENSOR............................14
INTAKE AIR TEMPERATURE SENSOR
DESCRIPTION.........................15
OPERATION...........................15
REMOVAL.............................15
INSTALLATION.........................15
CRANKSHAFT POSITION SENSOR
DESCRIPTION.........................15
OPERATION...........................15
MASS AIR FLOW (MAF) SENSOR
DESCRIPTION.........................16
OPERATION...........................16
REMOVAL.............................16
INSTALLATION.........................16
FUEL INJECTOR
DESCRIPTION
FUEL INJECTOR
There are individual fuel injectors for all four cyl-
inders. These fuel injectors are used to spray fuel
into the combustion chamber (Fig. 1).
OPERATION
The injector operation can be subdivided into four
operating states with the engine running and the
high-pressure pump generating pressure:
²Injector closed (with high pressure applied)
²Injector opens (start of injection)
²Injector opened fully
²Injector closes (end of injection)
Injector closed (with high pressure applied)
With the injector closed (at-rest state), the solenoid
valve is not energized and is therefore closed. With
the bleed orifice closed, the valve spring forces the
armature's ball onto the bleed-orifice seat. The rail's
high pressure build up in the valve control chamber,
and the same pressure is also present in the nozzle's
chamber volume. The rail pressure applied at the
control plunger's end face, together with the force of
Fig. 1 FUEL INJECTOR
1 - FUEL INJECTOR
2 - NOZZLE
3 - FUEL INLET FITTING
4 - ELECTRICAL CONNECTION
RGFUEL INJECTION14a-11
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the nozzle spring, maintain the nozzle in the closed
position against the opening forces applied to its
pressure stage (Fig. 2).
Injector opens (start of injection)
The solenoid valve is energized with the pickup
current which serves to ensure that it open quickly.The force exerted by the triggered solenoid now
exceeds that of the valve spring and the armature
opens the bleed orifice. Almost immediately, the high-
level pick-up current is reduced to the lower holding
current required for the electromagnet. This is possi-
ble due to the magnetic circuit's air gap now being
smaller. When the bleed orifice opens, fuel can flow
from the valve control chamber into the cavity situ-
ated above it, and from there via the fuel return to
the tank. The bleed orifice prevents complete pres-
sure balance, and the pressure in the valve control
chamber sinks as a result. This leads to the pressure
in the valve-control chamber being lower than that in
the nozzle's chamber volume which is still at the
same pressure level as the rail. The reduced pressure
in the valve-control chamber causes a reduction in
the force exerted on the control plunger, the nozzle
needle open as a result, and injection starts (Fig. 2).
Injector opens fully
The control plunger reaches its upper stop where it
remains supported by a cushion of fuel which is gen-
erated by the flow of fuel between the bleed and feed
orifices. The injector nozzle has now opened fully,
and the fuel is injected into the combustion chamber
at a pressure almost equal to that in the fuel rail
(Fig. 2).
Injector closes (end of injection)
As soon as the solenoid valve is no longer trig-
gered, the valve spring forces the armature down-
wards and the ball closes the bleed orifice. The
armature is a 2±piece design. Here, although the
armature plate is guided by a driver shoulder in its
downward movement, it can ªoverspringº with the
return spring so that it exerts no downwards-acting
forces on the armature and the ball. The closing of
the bleed orifice lead to pressure build up in the con-
trol chamber via the input from the feed orifice. This
pressure is the same as that in the rail and exerts an
increased force on the control plunger through its
end face. This force, together with that of the spring,
now exceeds the force exerted by the chamber volume
and the nozzle needle closes. Injection ceases as soon
as the nozzle needle comes up against its bottom stop
again (Fig. 2).
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE
COVER - REMOVAL).
(3) Disconnect injector electrical connector.
(4) Remove fuel return line from injector (Fig. 3).
(5) Remove fuel injector high pressure line (Fig. 3).
(6) Remove fuel injector retainer and retaining
bolt (Fig. 3).
Fig. 2 INJECTOR COMPONENTS
1 - INJECTOR CLOSED (AT-REST STATUS)
2 - ELECTRICAL CONNECTION
3 - TRIGGERING ELEMENT (SOLENOID VALVE)
4 - FUEL INLET (HIGH PRESSURE) FROM THE RAIL
5 - VALVE BALL
6 - BLEED ORIFICE
7 - FEED ORIFICE
8 - VALVE CONTROL CHAMBER
9 - VALVE CONTROL PLUNGER
10 - FEED PASSAGE TO THE NOZZLE
11 - NOZZLE NEEDLE
14a - 12 FUEL INJECTIONRG
FUEL INJECTOR (Continued)
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(7) Remove fuel injector from cylinder head (Fig.
3).
INSTALLATION
NOTE: Be sure the copper washer is installed on
end of injector before installing in cylinder head.
(1) Install fuel injector in cylinder head.(2) Install fuel injector retainer and bolt (Fig. 3).
Torque bolt to 32.4 N´m.
(3) Install fuel injector high pressure line (Fig. 3).
(4) Install fuel return line to injector (Fig. 3).
(5) Connect fuel injector electrical connector.
(6) Install engine cover (Refer to 9 - ENGINE
COVER - INSTALLATION).
(7) Connect negative battery cable.
ACCELERATOR PEDAL
POSITION SENSOR
DESCRIPTION
The accelerator pedal position sensor mounts to
the accelerator pedal bracket (Fig. 4).
OPERATION
The accelerator pedal position sensor contains a
potentiometer that is operated by the accelerator
pedal. As the accelerator pedal is depressed and
released, the sensor provides a variable voltage sig-
nal to the engine control module. This voltage signal
is directly proportional to accelerator pedal position.
When the pedal is fully depressed, the voltage signal
is high.
Fig. 3 FUEL SYSTEM COMPONENTS
1 - FUEL RAIL RETAINING BOLT
2 - FUEL RAIL RETAINING STUD
3 - FUEL RAIL RETURN LINE
4 - FUEL RAIL
5 - FUEL RAIL SUPPLY LINE
6 - IDLER PULLEY
7 - CRANKSHAFT PULLEY
8 - CRANKSHAFT PULLEY RETAINING BOLTS
9 - BELT TENSIONER RETAINING BOLT
10 - BELT TENSIONER
11 - FUEL INJECTOR RETAINER
12 - FUEL INJECTOR RETURN LINE
13 - FUEL INJECTOR RETAINING BOLT
14 - FUEL INJECTORS
15 - FUEL INJECTOR HIGH PRESSURE SUPPLY LINES
Fig. 4 ACCELERATOR PEDAL POSITION SENSOR
LOCATION (TYPICAL)
1 - ACCELERATOR PEDAL POSITION SENSOR ELECTRICAL
CONNECTOR
2 - ACCELERATOR PEDAL POSITION SENSOR
3 - ACCELERATOR PEDAL
4 - ACCELERATOR PEDAL MOUNTING BRACKET
RGFUEL INJECTION14a-13
FUEL INJECTOR (Continued)
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