service CHRYSLER VOYAGER 1996 Service Manual

leaks are not present. The component should be
replaced immediately if there is any evidence of deg-
radation that could result in failure.
Never attempt to repair a plastic fuel line/tube or a
quick±connect fitting. Replace complete line/tube as
necessary.
Avoid contact of any fuel tubes/hoses with other
vehicle components that could cause abrasions or
scuffing. Be sure that the fuel lines/tubes are prop-
erly routed to prevent pinching and to avoid heat
sources.
The lines/tubes/hoses are of a special construction.
If it is necessary to replace these lines/tubes/hoses,
use only original equipment type.
The hose clamps used to secure the rubber hoses
are of a special rolled edge construction. This con-
struction is used to prevent the edge of the clamp
from cutting into the hose. Only these rolled edge
type clamps may be used in this system. All other
types of clamps may cut into the hoses and cause
fuel leaks.
Where a rubber hose is joined to a metal tube
(staked), do not attempt to repair. Replace entire
line/tube assembly.
Use new original equipment type hose clamps.
Tighten hose clamps to 2 N´m (20 in. lbs.) torque.
QUICK-CONNECT FITTINGSÐLOW PRESSURE
TYPE
Different types of quick-connect fittings are used to
attach various fuel system components. These are: a
single-tab type, a two-tab type or a plastic retainer
ring type (Fig. 8). Refer to Quick-Connect Fittings in
the Removal/Installation section for more informa-
tion.
CAUTION: The interior components (o-rings, spac-
ers) of quick-connect fitting are not serviced sepa-
rately, but new pull tabs are available for some
types. Do not attempt to repair damaged fittings or
fuel lines/tubes. If repair is necessary, replace the
complete fuel tube assembly.
HIGH-PRESSURE FUEL LINES
CAUTION: The high±pressure fuel lines must be
held securely in place in their holders. The lines
cannot contact each other or other components. Do
not attempt to weld high±pressure fuel lines or to
repair lines that are damaged. Only use the recom-
mended lines when replacement of high±pressure
fuel line is necessary.
High±pressure fuel lines deliver fuel under pres-
sure of up to approximately 45,000 kPa (6526 PSI)
from the injection pump to the fuel injectors. Thelines 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 INJECTION
PRESSURE CAN CAUSE PERSONAL INJURY IF
CONTACT IS MADE WITH THE SKIN.
FUEL DRAIN TUBES
These rubber tubes are low±pressure type.
Some excess fuel is continually vented from the
fuel injection pump. During injection, a small amount
of fuel flows past the injector nozzle and is not
injected into the combustion chamber. This fuel
drains into the fuel drain tubes (Fig. 9) and back to
the tee banjo fitting, which is connected to the same
line as the overflow valve, which allows a variable
quantity to return to the fuel tank. The overflow
valve is calibrated to open at a preset pressure.
Excess fuel not required by the pump to maintain the
minimum pump cavity pressure is then returned
through the overflow valve and on to the fuel tank
through the fuel return line.
Fig. 8 Plastic Retainer Ring-Type Fitting
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 7
DESCRIPTION AND OPERATION (Continued)

DIAGNOSIS AND TESTING
GENERAL INFORMATION
This section of the group will cover a general diag-
nosis of diesel engine fuel system components.
Diagnostic Trouble Codes:Refer to On-Board
Diagnostics in Group 25, Emission Control System
for a list of Diagnostic Trouble Codes (DTC's) for cer-
tain fuel system components.
The PCM must be tested with the DRBIII scan
tool. The DRBIII should be the first step in any diag-
nosis of engine performance complaints. Refer to the
1997 GS 2.5L Diesel Powertrain Diagnostic Proce-
dures manual for diagnosis and testing of the diesel
engine control system.
VISUAL INSPECTION
A visual inspection for loose, disconnected, or incor-
rectly routed wires and hoses should be made before
attempting to diagnose or service the diesel fuel
injection system. A visual check will help find these
conditions. It also saves unnecessary test and diag-
nostic time. A thorough visual inspection of the fuel
injection system includes the following checks:
(1) Be sure that the battery connections are tight
and not corroded.
(2) Be sure that the 68 way connector is fully
engaged with the PCM (Fig. 12).
(3) Verify that the electrical connections for the
Diesel PCM relay are clean and free of corrosion.
This relay is located in the PDC. For the location ofthe relay within the PDC, refer to label on PDC
cover.
(4) Verify that the electrical connections for the
fuel heater relay are clean and free of corrosion. This
relay is located in the PDC. For the location of the
relay within the PDC, refer to label on PDC cover.
(5) Be sure the electrical connectors at the ends of
the glow plugs (Fig. 13) are tight and free of corro-
sion.
(6) Be sure that the electrical connections at the
glow plug relay are tight and not corroded. The glow
plug relay is located in the engine compartment on
the left±inner fender (Fig. 14).
Fig. 12 PCM LocationÐTypical
Fig. 13 Glow Plug Connector
Fig. 14 Glow Plug Relay Location
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 9

the intake manifold. Refer to Group 11, Exhaust Sys-
tem and Intake Manifold for information.
(21) Be sure that the vacuum hoses to the vacuum
pump are connected and not leaking. The pump is
located on the front of engine (internal) and is driven
from the crankshaft gear and chain (Fig. 20). Discon-
nect the hose and check for minimum vacuum from
the pump. Refer to Group 5, Brake System for spec-
ifications and procedures.(22) Be sure that the accessory drive belt is not
damaged or slipping.
(23) Verify there is a good connection at the engine
speed sensor. Refer to the Fuel Injection System in
this section for location of the engine speed sensor
location.
(24) Verify there is a good connection at the Mass
Air Flow Sensor, which is a part of the air intake
assembly.
AIR IN FUEL SYSTEM
Air will enter the fuel system whenever the fuel
supply lines, fuel filter/water separator, fuel filter
bowl, injection pump, high±pressure lines or injectors
are removed or disconnected. Air will also enter the
fuel system whenever the fuel tank has been run
empty.
Air trapped in the fuel system can result in hard
starting, a rough running engine, engine misfire, low
power, excessive smoke and fuel knock. After service
is performed, air must be bled from the system
before starting the engine.
Inspect the fuel system from the fuel tank to the
injectors for loose connections. Leaking fuel is an
indicator of loose connections or defective seals. Air
can also enter the fuel system between the fuel tank
and the injection pump. Inspect the fuel tank and
fuel lines for damage that might allow air into the
system.
For air bleeding, refer to Air Bleed Procedure in
the Service Procedures section of this group.
Fig. 18 Vehicle Speed SensorÐTypical
Fig. 19 Engine Coolant Temperature Sensor
Location
Fig. 20 Vacuum Pump at Front of Engine
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 11
DIAGNOSIS AND TESTING (Continued)

FUEL HEATER RELAY TEST
The fuel heater relay is located in the Power Dis-
tribution Center (PDC). Refer to RelaysÐOperation/
Testing in Fuel Ingection System section of this
group for test procedures.
FUEL INJECTOR TEST
The fuel injection nozzels, located on the engine
cylinder head, spray fuel under high pressure into
the individual combustion chambers. Pressurized
fuel, delivered by the fuel injection pump, unseats a
spring-loaded needle valve inside the injector, and
the fuel is atomized as it escapes through the injector
opening into the engine's combustion chamber. If the
fuel injector does not operate properly, the engine
may misfire, or cause other driveability problems.
A leak in the injection pump±to±injector high±pres-
sure fuel line can cause many of the same symptoms
as a malfunctioning injector. Inspect for a leak in the
high±pressure lines before checking for a malfunc-
tioning fuel injector.
WARNING: THE INJECTION PUMP SUPPLIES HIGH-
±PRESSURE FUEL OF UP TO APPROXIMATELY
45,000 KPA (6526 PSI) TO EACH INDIVIDUAL INJEC-
TOR THROUGH THE HIGH±PRESSURE LINES. FUEL
UNDER THIS AMOUNT OF PRESSURE CAN PENE-
TRATE THE SKIN AND CAUSE PERSONAL INJURY.
WEAR SAFETY GOGGLES AND ADEQUATE PRO-
TECTIVE CLOTHING. AVOID CONTACT WITH FUEL
SPRAY WHEN BLEEDING HIGH±PRESSURE FUEL
LINES.
WARNING: DO NOT BLEED AIR FROM THE FUEL
SYSTEM OF A HOT ENGINE. DO NOT ALLOW FUEL
TO SPRAY ONTO THE EXHAUST MANIFOLD WHEN
BLEEDING AIR FROM THE FUEL SYSTEM.
To determine which fuel injector is malfunctioning,
run the engine and loosen the high±pressure fuel line
nut at the injector (Fig. 21). Listen for a change in
engine speed. If engine speed drops, the injector was
operating normally. If engine speed remains the
same, the injector may be malfunctioning. After test-
ing, tighten the line nut to 30 N´m (22 ft. lbs.)
torque. Test all injectors in the same manner one at
a time.
Once an injector has been found to be malfunction-
ing, remove it from the engine and test it. Refer to
the Removal/Installation section of this group for pro-
cedures.
After the injector has been removed, install it to a
bench±mount injector tester. Refer to operating
instructions supplied with tester for procedures.
The opening pressure or ªpopº pressure should be
15,000±15,800 kPa (2175±2291 psi). If the fuel injec-tor needle valve is opening (ªpoppingº) to early or to
late, replace the injector.
FUEL INJECTOR SENSOR TEST
The fuel injector sensor is used only on the fuel
injector for the number±1 cylinder (Fig. 22). It is not
used on the injectors for cylinders number 2, 3, or 4.
To test the sensor, unplug the sensor connector
(Fig. 22) from the engine wiring harness. Check
resistance across terminals. Resistance should be 110
ohms610 ohms at 20ÉC (68ÉF). Replace sensor if
specification cannot be met.
FUEL INJECTION PUMP TEST
The injection pump is not to be serviced or
the warranty may be voided. If the injection
pump requires service, the complete assembly
must be replaced.
Incorrect injection pump timing (mechanical or
electrical) can cause poor performance, excessive
smoke and emissions and poor fuel economy.
Fig. 21 Typical Inspection of Fuel Injector
Fig. 22 Fuel Injector Sensor Location
14 - 12 FUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINENS/GS
DIAGNOSIS AND TESTING (Continued)

START positions, fuel supply is allowed at the injec-
tion pump.
(1) Disconnect the electrical pigtail connector (test
connector) (Fig. 23) from the main engine wiring har-
ness. Do not disconnect wiring directly at solenoid.
(2) Connect the leads of a voltmeter between a
good ground and the disconnected engine wiring har-
ness.
(3) Turn the key to the ON position. Do not
attempt to start engine.
(4) 12V+ should be observed at wiring harness. If
not, refer to Group 8, Wiring for wiring schematics
and repair as necessary.
(5) T
urn the key to the START position. 12V+ should
be observed at wiring harness. If not, refer to Group 8,
Wiring for wiring schematics and repair as necessary.
The fault may be in the ignition (key) switch.
12V+ must be observed in both the ON and START
positions. If 12V+ was observed, proceed to the next
step.
(6) With key still in the ON position, connect and
disconnect the wiring harness to the solenoid. As this
is done, a clicking noise should be heard coming from
the solenoid. If not, replace solenoid. Refer to Fuel
Shutdown Solenoid in the Removal/Installation sec-
tion of this group for procedures.
HIGH-PRESSURE FUEL LINE LEAK TEST
High±pressure fuel line leaks can cause starting
problems and poor engine performance.
WARNING: DUE TO EXTREME FUEL PRESSURES
OF UP TO 45,000 KPA (6526 PSI), USE EXTREME
CAUTION WHEN INSPECTING FOR HIGH±PRESSURE
FUEL LEAKS. DO NOT GET YOUR HAND, OR ANY
PART OF YOUR BODY 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. 24). If a high±pressure line con-
nection is leaking, bleed the system and tighten the
connection. 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.
CAUTION: The high±pressure fuel lines must be
clamped securely in place in the holders. The lines
cannot contact each other or other components. Do
not attempt to weld high±pressure fuel lines or to
repair lines that are damaged. Only use the recom-
mended lines when replacement of high±pressure
fuel line is necessary.
WASTEGATE (TURBOCHARGER)
Refer to Group 11, Exhaust System and Intake
Manifold for information.
SERVICE PROCEDURES
AIR BLEED PROCEDURES
AIR BLEEDING AT FUEL FILTER
A certain amount of air may become trapped in the
fuel system when fuel system components are ser-
viced or replaced. Bleed the system as needed after
fuel system service according to the following proce-
dures.
WARNING: DO NOT BLEED AIR FROM THE FUEL
SYSTEM OF A HOT ENGINE. DO NOT ALLOW FUEL
TO SPRAY ONTO THE EXHAUST MANIFOLD WHEN
BLEEDING AIR FROM THE FUEL SYSTEM.
Some air enters the fuel system when the fuel fil-
ter or injection pump supply line is changed. This
small amount of air is vented automatically from the
injection pump through the fuel drain manifold tubes
if the filter was changed according to instructions.
Ensure the bowl of the fuel filter/water separator is
full of fuel
It may be necessary to manually bleed the system
if:
²The bowl of the fuel filter/water separator is not
partially filled before installation of a new filter
²The injection pump is replaced
Fig. 24 Typical Test for Leaks with Cardboard
14 - 14 FUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINENS/GS
DIAGNOSIS AND TESTING (Continued)

²High±pressure fuel line connections are loosened
or lines replaced
²Initial engine start±up or start±up after an
extended period of no engine operation
²Running fuel tank empty
FUEL INJECTION PUMP BLEEDING
(1) If the fuel injection pump has been replaced,
air should be bled at the overflow valve before
attempting to start engine.
(a) Loosen the overflow valve (Fig. 25) at the
rear of the injection pump.
(b) Place a towel below the valve.
WARNING: WHEN CRANKING THE ENGINE TO
BLEED AIR FROM THE INJECTION PUMP, THE
ENGINE MAY START. PLACE THE TRANSMISSION
IN NEUTRAL OR PARK AND SET PARKING BRAKE
BEFORE ENGAGING THE STARTER MOTOR.
CAUTION: Do not engage the starter motor for
more than 30 seconds at a time. Allow 2 minutes
between cranking intervals.
(2) Crank the engine for 30 seconds at a time to
allow air trapped in the injection pump to vent out
the fuel injector drain tubes. Continue this procedure
until the engine starts. Observe the previous WARN-
ING and CAUTION.
(3) Tighten overflow valve.
HIGH±PRESSURE FUEL LINE BLEEDING
WARNING: THE INJECTION PUMP SUPPLIES HIGH-
±PRESSURE FUEL OF APPROXIMATELY 59,000 KPA
(8,557 PSI) TO EACH INDIVIDUAL INJECTOR
THROUGH THE HIGH±PRESSURE LINES. FUEL
UNDER THIS AMOUNT OF PRESSURE CAN PENE-
TRATE THE SKIN AND CAUSE PERSONAL INJURY.
WEAR SAFETY GOGGLES AND ADEQUATE PRO-
TECTIVE CLOTHING AND AVOID CONTACT WITH
FUEL SPRAY WHEN BLEEDING HIGH±PRESSURE
FUEL LINES.
WARNING: DO NOT BLEED AIR FROM THE FUEL
SYSTEM OF A HOT ENGINE. DO NOT ALLOW FUEL
TO SPRAY ONTO THE EXHAUST MANIFOLD WHEN
BLEEDING AIR FROM THE FUEL SYSTEM.
Bleed air from one injector at time.
(1) Loosen the high±pressure fuel line fitting at
the injector (Fig. 26).
(2) Crank the engine until all air has been bled
from the line.Do not operate the starter motor
for longer than 30 seconds. Wait 2 minutes
between cranking intervals.
(3) Start the engine and bleed one injector at a
time until the engine runs smoothly.
FUEL INJECTION PUMP TIMING
Refer to Removal/Installation and Adjusting Fuel
Pump Timing in this Group.
Fig. 25 Overflow Valve
Fig. 26 Bleeding High±Pressure Fuel LineÐTypical
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 15
SERVICE PROCEDURES (Continued)

FUEL LEVEL SENSOR
REMOVAL
Remove fuel reservoir module. Refer to Fuel Reser-
voir Module in this section.
(1) Depress retaining tab and remove the level
sensor connector from theBOTTOMof the fuel mod-
ule electrical connector (Fig. 31).
NOTE: The pump module harness on TOP of flange
is not serviceable or removable.
(2) Pull off blue locking wedge (Fig. 32).
(3) Using a small screwdriver lift locking finger
away from terminal and push terminal out of connec-
tor (Fig. 33).
(4) Push level sensor signal and ground terminals
out of the connector (Fig. 34).(5) Insert a screwdriver between the fuel module
and the top of the level sensor housing (Fig. 35).
Push level sensor down slightly.
(6) Slide level sensor wires through opening fuel
module (Fig. 36).
(7) Slide level sensor out of installation channel in
module.
Fig. 31 Fuel Module/Level Sensor Electrical
Connector
Fig. 32 Wire Terminal Locking Wedge
Fig. 33 Wire Terminal Locking Finger
Fig. 34 Removing Wires From Connector
Fig. 35 Loosening Level Sensor
14 - 18 FUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

(14) Gauge reading should be at 0.60 mm. If not,
the pump must be rotated for adjustment:
(a) Loosen the three injection pump mounting
nuts at the mounting flanges. These flanges are
equipped with slotted holes. The slotted holes are
used to rotate and position the injection pump for
fuel timing. Loosen the three nuts just enough to
rotate the pump.
(b) Rotate the pumpclockwise(as viewed from
front) until .60 mm is indicated on the dial indica-
tor gauge.
(c) Tighten the three pump mounting nuts to 30
N´m (22 ft. lbs.) torque.
(d) Recheck the dial indicator after tightening
the pump mounting nuts. Gauge should still be
reading 0.60 mm. Loosen pump mounting nuts and
readjust if necessary.
(15) Remove dial indicator and adapter tools.
(16) Install access plug and washer to rear of
injection pump.
(17) Install plug at timing gear cover.
(18) Remove dial indicator from valve stem.
(19) Install valve spring and keepers.
(20) Install rocker arm assembly and tighten nuts.
(21) Install and connect the four high±pressure
fuel lines to the fuel injection pump. Also connect
fuel lines at the fuel injectors. For procedures, refer
to High±Pressure Fuel Lines in this group.
(22) Install electrical connector at engine coolant
temperature sensor.
(23) Connect electrical connector at fuel shutdown
solenoid.(24) Connect the main engine wiring harness to
the glow plugs.
(25) Connect the fuel timing solenoid pigtail har-
ness to the engine wiring harness.
(26) Connect the overflow valve/banjo fitting (fuel
return line assembly). Replace copper gaskets before
installing.
(27) Connect the rubber fuel return and supply
hoses to metal lines at pump. Tighten hose clamps to
2 N´m (20 in. lbs.) torque.
(28) Install generator assembly.
(29) Install engine accessory drive belt. Refer to
Group 7, Cooling System for procedures.
(30) Install negative battery cable to battery.
(31) Start the engine and bring to normal operat-
ing temperature.
(32) Check for fuel leaks.
FUEL INJECTORS
Four fuel injectors are used on each engine. Of these
four, two different types are used. The fuel injector used
on cylinder number one is equipped with a fuel injector
sensor (Fig. 47). The other three fuel injectors are iden-
tical.
Do not place the fuel injector equipped with
the fuel injector sensor into any other location
except the cylinder number one position.
REMOVAL
(1) Disconnect negative battery cable at battery.
(2) Thoroughly clean the area around the injector
with compressed air.
(3) Remove the fuel drain hoses (tubes) at each
injector (Fig. 48) being serviced. Each of these hoses
is slip±fit to the fitting on injector.
(4) Remove the high±pressure fuel line at injector
being removed. Refer to High±Pressure Fuel Lines in
this group for procedures.
(5) Remove the injector using special socket tool
number VM.1012A. When removing cylinder number
Fig. 46 Installing Dial Indicator and Special Adapter
Tools
Fig. 47 Fuel Injector SensorÐNumber±1 Cylinder
14 - 22 FUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

FUEL DELIVERY SYSTEMÐ2.0L ENGINE
INDEX
page page
DESCRIPTION AND OPERATION
ELECTRIC FUEL PUMP.................. 28
FUEL DELIVERY SYSTEM................ 28
FUEL INJECTORS...................... 28
FUEL LEVEL SENSOR................... 28
FUEL PRESSURE REGULATOR........... 28
FUEL PUMP MODULE................... 28
FUEL TANK........................... 28
PRESSURE-VACUUM FILLER CAPÐ
2.0L ENGINE......................... 28
QUICK-CONNNECT FITTINGSÐ
2.0L ENGINE......................... 28
DIAGNOSIS AND TESTING
FUEL INJECTORSÐ2.0L ENGINE.......... 29
FUEL LEVEL SENSORÐ2.0L ENGINE....... 28
FUEL PUMP PRESSURE TESTÐ
2.0L ENGINE......................... 28SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE
PROCEDUREÐ2.0L ENGINE............ 29
HOSES AND CLAMPSÐ2.0L ENGINE....... 29
QUICK-CONNNECT FITTINGSÐ2.0L ENGINE . 29
REMOVAL AND INSTALLATION
ACCELERATOR PEDAL.................. 31
FUEL FILTERÐ2.0L ENGINE.............. 29
FUEL INJECTORS...................... 30
FUEL LEVEL SENSORÐ2.0L ENGINE....... 30
FUEL PRESSURE REGULATORÐ
2.0L ENGINE......................... 29
FUEL PRESSURE REGULATORÐ
2.0L ENGINE......................... 29
FUEL PUMP MODULEÐ2.0L ENGINE....... 29
FUEL TANKÐ2.0L ENGINE............... 30
TORQUE SPECIFICATION................ 31
DESCRIPTION AND OPERATION
FUEL DELIVERY SYSTEM
Refer to the Fuel Delivery Sytem in the Fuel Deliv-
ery Section of group 14 for the 2.4/3.0/3.3/3.8L
engines for more information.
FUEL PUMP MODULE
Refer to the Fuel Pump Module for the 2.4/3.0/3.3/
3.8L engines in the Fuel Delivery System section of
group 14.
ELECTRIC FUEL PUMP
Refer to the Electric Fuel Pump for the 2.4/3.0/3.3/
3.8L engines in the Fuel Delivery System Section of
group 14 for more information.
FUEL LEVEL SENSOR
Refer to the Fuel Level Sensor for the 2.4/3.0/3.3/
3.8L engines in the Fuel Delivery System section of
group 14 for more information.
FUEL PRESSURE REGULATOR
Refer to the Fuel Pressure Regulator for the 2.4/
3.0/3.3/3.8L engines in the Fuel Delivery System sec-
tion of group 14 for more information.
FUEL INJECTORS
Refer to the Fuel Injectors for the 2.4/3.0/3.3/3.8L
engines in the Fuel Delivery System section of group
14 for more information.
FUEL TANK
Refer to the Fuel Tank for the 2.4/3.0/3.3/3.8L
engines in the Fuel Delivery System section of group
14 for more information.
PRESSURE-VACUUM FILLER CAPÐ2.0L ENGINE
Refer to the Pressure-Vacuum Filler Cap for the
2.4/3.0/3.3/3.8L engines in the Fuel Delivery System
section of group 14 for more information.
QUICK-CONNNECT FITTINGSÐ2.0L ENGINE
Refer to the Quick Connect Fittings for the 2.4/3.0/
3.3/3.8L engines in the Fuel Delivery System section
of group 14 for more information.
DIAGNOSIS AND TESTING
FUEL PUMP PRESSURE TESTÐ2.0L ENGINE
Refer to the Fuel Pressure Test for the 2.4/3.0/3.3/
3.8L engines in the Fuel Delivery System section of
group 14 for more information.
FUEL LEVEL SENSORÐ2.0L ENGINE
Refer to the Fuel Level Sensor for the 2.4/3.0/3.3/
3.8L engines in the Fuel Delivery System section of
group 14 for more information.
14 - 28 FUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINENS/GS

FUEL INJECTORSÐ2.0L ENGINE
Refer to the Fuel Injectors for the 2.4/3.0/3.3/3.8L
engines in the Fuel Delivery System section of group
14 for more information.
SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE
PROCEDUREÐ2.0L ENGINE
Refer to the Fuel System Pressure Release Proce-
dure for the 2.4/3.0/3.3/3.8L engines in the Fuel
Delivery System section of group 14 for more infor-
mation.
HOSES AND CLAMPSÐ2.0L ENGINE
Refer to Hoses and Clamps for the 2.4/3.0/3.3/3.8L
engines in the Fuel Delivery System section of group
14 for more information.
QUICK-CONNNECT FITTINGSÐ2.0L ENGINE
Refer to the Quick Connect Fittings for the 2.4/3.0/
3.3/3.8L engines under Service Procedures in the
Fuel Delivery System section of group 14 for more
information.
REMOVAL AND INSTALLATION
FUEL FILTERÐ2.0L ENGINE
Refer to the Fuel Filter for the 2.4/3.0/3.3/3.8L
engines under Removal and Installation in the Fuel
Delivery System section of group 14 for more infor-
mation.
FUEL PUMP MODULEÐ2.0L ENGINE
Refer to the Fuel Pump Module for the 2.4/3.0/3.3/
3.8L engines under Removal and Installation in theFuel Delivery System section of group 14 for more
information.
FUEL PRESSURE REGULATORÐ2.0L ENGINE
Refer to the Fuel Pressure Rgulator for the 2.4/3.0/
3.3/3.8L engines under Removal and Installation in
the Fuel Delivery System section of group 14 for
more information.
FUEL PRESSURE REGULATORÐ2.0L ENGINE
Refer to the Fuel Pressure Regulator for the 2.4/
3.0/3.3/3.8L engines under Removal and Installation
in the Fuel Delivery System section of group 14 for
more information.
Fig. 1 Fuel Pressure Test PortÐ2.0L
Fig. 2 FUEL LEVEL SENSOR DIAGNOSIS
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 29
DIAGNOSIS AND TESTING (Continued)