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Throughout this group, references are made to a particular vehicle by letter designation. A chart showing the breakdown of these designations is included in the Introduction Section at the front of this service manual.

The Fuel System consists of the fuel tank, fuel pump, fuel filter, throttle body, fuel injectors, fuel lines and vacuum lines.

The Fuel Delivery System consists of the fuel pump, fuel filter, fuel lines and fuel hoses.

The Fuel Tank Assembly consists of the fuel tank, filler tube, a fuel gauge sending unit assembly and a pressure-vacuum filler cap.

Also, the Evaporation Control System is part of the fuel system. The evaporation control system is designed to reduce the emission of fuel vapor into the atmosphere.

The description and function of the Evaporation Control System is found in Group 25 of this manual.

FUEL REQUIREMENTS

Your vehicle was designed to meet all emission regulations and provide excellent fuel economy when using high quality unleaded gasoline.

VEHICLES WITHOUT TURBOCHARGED ENGINES

Use unleaded gasoline having a minimum octane rating of 87.

VEHICLES WITH TURBOCHARGED ENGINESÐEXCEPT 16 VALVE 2.2L ENGINES

These vehicles will operate satisfactorily on both regular unleaded gasoline having a minimum octane rating or 87, and premium unleaded gasoline having a minimum octane rating of 91. The use of premium unleaded gasoline will improve performance.

VEHICLES WITH 2.2L 16 VALVE ENGINES

The use of premium unleaded gasoline having a minimum octane of 91 is recommended. If premium unleaded is not available, then unleaded gasoline with a minimum octane of 87 may be used. However, the use of lower octane gasoline will result in reduced performance.

THE FOLLOWING IS APPLICABLE TO ALL VEHICLES

Light spark knock at low engine speeds is not harmful to your engine. However, continued heavy spark knock at high speeds can cause damage and should be reported to your dealer immediately. En-

14 - 2 FUEL SYSTEMS

gine damage resulting from operating with a heavy spark knock may not be covered by the new vehicle warranty.

In addition to using unleaded gasoline with the proper octane rating, gasolines that contain detergents, corrosion and stability additives are recommended. Using gasolines that have these additives will help improve fuel economy, reduce emissions, and maintain vehicle performance. Generally, premium unleaded gasolines contain more additive than regular unleaded.

Poor quality gasoline can cause problems such as hard starting, stalling, and stumble. If you experience these problems, try another brand of gasoline before considering service for the vehicle.

GASOLINE/OXYGENATE BLENDS

Some fuel suppliers blend gasoline with materials that contain oxygen such as alcohol, MTBE (Methyl Tertiary Butyl Ether) and ETBE (Ethyl Tertiary Butyl Ether). The type and amount of oxygenate used in the blend is important.

The following are generally used in gasoline blends: Ethanol - (Ethyl or Grain Alcohol) properly blended, is used as a mixture of 10 percent ethanol and 90 percent gasoline. Gasoline blended with etha-

nol may be used in your vehicle.

Methanol - (Methyl or Wood Alcohol) is used in a variety of concentrations when blended with unleaded gasoline. You may find fuels containing 3 percent or more methanol along with other alcohols called cosolvents.

Do not use gasolines containing Methanol.

Use of methanol/gasoline blends may result in starting and driveability problems and damage critical fuel system components.

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Problems that are the result of using methanol/gasoline blends are not the responsibility of Chrysler Motors and may not be covered by the new vehicle warranty.

MTBE/ETBE - Gasoline and MTBE (Methyl Tertiary Butyl Ether) blends are a mixture of unleaded gasoline blended and up to 15 percent MTBE. Gasoline and ETBE (Ethyl Tertiary Butly Ether) are blends of gasoline and up to 17 percent ETBE. Gasoline blended with MTBE or ETBE may be used in your vehicle.

Clean Air Gasoline

Many gasolines are now being blended that contribute to cleaner air, especially in those areas of the country where pollution levels are high. These new blends provide a cleaner burning fuel and some are referred to as reformulated gasoline.

In areas of the country where carbon monoxide levels are high, gasolines are being treated with oxygenated materials such as ETBE, MTBE and ethanol. The use of gasoline blended with these materials also contributes to cleaner air.

Chrysler Corporation supports these efforts toward cleaner air and recommends that you use these gasolines as they become available.

Materials Added to Fuel

Indiscriminate use of fuel system cleaning agents should be avoided. Many of these materials intended for gum and varnish removal may contain active solvents of similar ingredients that can be harmful to fuel system gasket and diaphragm materials.

GENERAL INFORMATION

FUEL SYSTEM PRESSURE RELEASE PROCEDURE

(1)Loosen fuel filler cap to release fuel tank pres-

sure.

(2)Disconnect injector wiring harness from engine or main harness.

(3)Connect a jumper wire from terminal Number 1 (ground) of the injector harness (Fig. 1) to engine ground.

(4)Connect one end of a jumper wire to terminal Number 2 (positive) of the injector harness (Fig. 1). Connect the other end to the positive post of the battery for no longer than 5 seconds. This releases system pressure.

(5)Remove jumper wires.

(6)Continue fuel system service.

Fig. 1 Injector Harness Connections

FUEL HOSES, CLAMPS, AND QUICK CONNECT FITTINGS

HOSES AND CLAMPS

Inspect all hose connections (clamps and quick connect fittings) for completeness and make sure they are not leaking. Hoses that are cracked, scuffed, swelled, rub against other vehicle components or show any sign of wear, should be replaced.

Fuel injected vehicles use specially constructed hoses. When replacing hoses, only use hoses marked EFM/ EFI.

When installing hoses, ensure they are routed away from contact with other vehicle components that could rub against them and cause failure. Avoid contact with clamps or other components that cause abrasions or scuffing. Ensure that rubber hoses are properly routed and avoid heat sources.

The hose clamps have rolled edge to prevent the clamp from cutting into the hose. Only use clamps that are original equipment or equivalent. Other types of clamps may cut into the hoses and cause high pressure fuel leaks. Tighten hose clamps to 1 NIm (10 in. lbs.) torque.

QUICK CONNECT FITTINGS

Some fuel lines have quick connect fittings. The fittings are designed to speed up the installation and removal of the fuel lines (Fig. 2).

Quick connect fittings consist of a metal casing, a black plastic release ring, a metal locking retainer, and internal O-rings.

TUBE/FITTING DISASSEMBLY

WARNING: FUEL SYSTEM PRESSURE MUST BE RELEASED BEFORE DISCONNECTING ANY FUEL SYSTEM COMPONENT.

(1)Disconnect the negative battery cable.

(2)Remove the fuel tank gas cap to release fuel tank pressure.

(3)Perform the Fuel System Pressure Release Procedure.

Fig. 2 Quick Connect Fuel Fittings

(4) Remove any loose dirt from quick connect fittings.

WARNING: WRAP SHOP TOWELS AROUND HOSES TO CATCH ANY GASOLINE SPILLAGE.

(5)To remove the fuel tube nipple from a quick connect fitting, pull back on the fitting while pushing in on the plastic ring (Fig. 2). To aid in disassembly, an open end wrench may be used to push the plastic ring in.

(6)Cover the quick connector to prevent contamination.

TUBE/FITTING ASSEMBLY

(1)Inspect the quick connect fitting to ensure the black plastic release ring is in the OUT position. If the locking retainer is stuck in the RELEASE position due to mushrooming of the release ring or dirt accumulation, the fitting should be replaced.

Fuel tube nipples must be lubricated with clean 30 weight engine oil prior to reconnecting the quick-connect fitting.

(2)Lubricate the fuel tube nipple with clean 30 weight engine oil.

(3)Insert fuel tube nipple into the quick connector fitting. When the fuel tube nipple enters the quickconnect fitting, the nipple shoulder is held in place by the locking retainer. The internal O-rings seal the tube.

(4)Pull back on the quick connect fitting to verify the connection is secure. The tube should be locked in place. If the connection is not complete, make sure the black plastic release is not causing the locking retainer to jam in the release position.

CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) Relay remains energized for either 7 minutes, until the test is stopped, or until the ignition switch is turned to the Off position.

(5) Use the DRB II ASD Fuel System Test to pressurize the fuel system. Check for leaks.

TUBE/FITTING SERVICE

If a quick connect fitting needs service, the following procedure must be followed:

(1)Disconnect the battery negative battery cable.

(2)Perform the Fuel System Pressure Release Procedure.

WARNING: WRAP SHOP TOWELS AROUND HOSES TO CATCH ANY GASOLINE SPILLAGE.

(3)Remove the quick connect fitting from the fuel tube by pushing in on the plastic ring located on the end of the fitting. Gently pull the fitting from the fuel tube.

(4)Cut off the crimp ferrules at each end of the hose, taking care not to damage the quick connect fitting or the fuel tube.

(5)Discard the ferrules and hose. Discard the quick connect fitting if it is defective.

(6)Replace the hose using hose marked EFM/EFI.

(7)Replace the quick connect fittings (if necessary) with the correct size and type.

(8)Attach the replacement hose to the quick connect fitting and fuel tube using the correct hose clamps. Original equipment hose clamps have a special rolled edge construction to prevent the edge of the clamp cutting into the hose. Only original equipment clamps or equivalent may be used in this system. Other types of clamps may cut into the hoses and cause high pressure fuel leaks.

(9)Tighten hose clamps to 1 NIm (10 in. lbs.) torque.

CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) Relay remains energized for either 7 minutes, until the test is stopped, or until the ignition switch is turned to the Off position.

(10) Use the DRB II ASD Fuel System Test to pressurize the fuel system. Check for leaks.

FUEL PUMP ASSEMBLY

The fuel pump assembly consists of the fuel pump and the reservoir body.

The reservoir body takes the place of an internal fuel tank reservoir. The reservoir maintains fuel at the pump inlet during all driving conditions, especially when the fuel level is low.

The system uses a positive displacement, gerotor gear, immersible pump with a permanent magnet electric motor (Fig. 3). The pump draws fuel through a strainer and pushes it through the electric motor to the outlet. The pump contains three check valves. One valve relieves internal fuel pump pressure and regulates maximum pump output. Another valve, in-