2001 CHRYSLER VOYAGER Service Manual

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Page 2873 of 4284

CHRYSLER VOYAGER 2001 Service Manual FUEL SYSTEM
TABLE OF CONTENTS
page page
FUEL DELIVERY..........................1FUEL INJECTION........................16
FUEL DELIVERY
TABLE OF CONTENTS
page page
FUEL DELIVERY
DESCRIPTION............

FUEL SYSTEM
TABLE OF CONTENTS
page page
FUEL DELIVERY..........................1FUEL INJECTION........................16
FUEL DELIVERY
TABLE OF CONTENTS
page page
FUEL DELIVERY
DESCRIPTION............................1
OPERATION.............................2
DIAGNOSIS AND TESTING..................2
FUEL DELIVERY SYSTEM.................2
STANDARD PROCEDURE...................2
FUEL PRESS RELEASE...................2
STANDARD PROCEDURE.................2
SPECIFICATIONS.........................2
SPECIAL TOOLS..........................3
FUEL FILTER
REMOVAL...............................4
INSTALLATION............................4
FUEL LEVEL SENDING UNIT / SENSOR
DESCRIPTION............................4
OPERATION.............................4
REMOVAL...............................4
INSTALLATION............................5
FUEL LINES
DESCRIPTION............................6
STANDARD PROCEDURE...................6
HOSES & CLAMP........................6
FUEL PRESSURE REGULATOR
OPERATION.............................6
REMOVAL...............................7
INSTALLATION............................7
FUEL PUMP
DESCRIPTION............................7OPERATION.............................7
FUEL PUMP MODULE
DESCRIPTION............................7
OPERATION.............................7
REMOVAL...............................8
INSTALLATION............................8
FUEL RAIL
REMOVAL...............................9
INSTALLATION............................9
FUEL TANK
DESCRIPTION...........................10
OPERATION.............................10
REMOVAL..............................10
INSTALLATION...........................11
FUEL TANK FILLER TUBE
REMOVAL..............................12
INSTALLATION...........................12
INLET FILTER
REMOVAL..............................13
INSTALLATION...........................13
QUICK CONNECT FITTING
STANDARD PROCEDURE..................13
QUICK CONNECT FITTING...............13
ROLLOVER VALVE
DESCRIPTION...........................15
OPERATION.............................15
FUEL DELIVERY
DESCRIPTION
The front wheel drive car uses a plastic fuel tank
located rear center of the vehicle.
The Fuel Delivery System consists of: the following
items:²Electric fuel pump module
²Fuel filter
²Tubes/lines/hoses
²Fuel injectors
The in-tank fuel pump module contains the fuel
pump. The pump is serviced as part of the fuel pump
module. Refer to Fuel Pump Module.
RSFUEL SYSTEM14-1

Page 2874 of 4284

CHRYSLER VOYAGER 2001 Service Manual The fuel filter is replaceable, it is mounted on the
outside and on top of the fuel tank. Refer to the
Maintenance Schedules in the Introduction section of
this manual for recommended fuel filter repl

The fuel filter is replaceable, it is mounted on the
outside and on top of the fuel tank. Refer to the
Maintenance Schedules in the Introduction section of
this manual for recommended fuel filter replacement
intervals.
FFV REPLACEMENT PARTS
Many components in a Flexible Fuel Vehicle (FFV)
are designed to be compatible with ethanol. Always
be sure that the vehicle is serviced with correct etha-
nol compatible parts.
CAUTION: Replacing fuel system components with
non-ethanol compatible components can damage
your vehicle and may void the warranty.
OPERATION
The fuel system is provided fuel pressure by an in-
tank pump module. The PCM controls the operation
of the fuel system by providing battery voltage to the
fuel pump through the fuel pump relay. The PCM
requires only three inputs and a good ground to oper-
ate the fuel pump relay. The three inputs are:
²Ignition voltage
²Crankshaft Position (CKP) sensor
²Camshaft Position (CMP) sensor
DIAGNOSIS AND TESTING - FUEL DELIVERY
SYSTEM
(Refer to Appropriate Diagnositic Information)
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE PROCEDURE
(1) Remove Fuel Pump relay from Power Distribu-
tion Center (PDC). For location of relay, refer to label
on underside of PDC cover.(2) Start and run engine until it stalls.
(3) Attempt restarting engine until it will no
longer run.
(4) Turn ignition key to OFF position.
(5) Place a rag or towel below fuel line quick-con-
nect fitting at fuel rail.
(6) Return fuel pump relay to PDC.
(7) One or more Diagnostic Trouble Codes (DTC's)
may have been stored in PCM memory due to fuel
pump relay removal. The DRB IIItscan tool must be
used to erase a DTC.
STANDARD PROCEDURE - DRAINING FUEL
TANK
(1) Release fuel system pressure, refer to the Fuel
System Release Procedure in this section.
(2) Insert a 1/4 inch siphon (max. O. D. 5/16) hose
from a portable fuel siphoning tank through the fuel
filler neck opening into the fuel tank. Hose most
have a 30 degree angle cut on the end to bypass the
check valve in the end of the filler neck. Refer to the
siphoning tank's Manufacturing Instructions.
(3) Drain fuel from fuel tank into siphoning tank.
SPECIFICATIONS
FUEL SYSTEM PRESSURE
400 kpa634 kpa (58 psi65 psi)
TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Fuel Rail 2.4L 22 200
Fuel Rail 3.3/3.8L 11.8 105
Fuel Tank Strap 54 40
Fuel Tank T Strap 28.2 250
Fuel Filter Bolt 4.5 40
14 - 2 FUEL DELIVERYRS
FUEL DELIVERY (Continued)

Page 2875 of 4284

CHRYSLER VOYAGER 2001 Service Manual SPECIAL TOOLS
FUEL
Pressure Gauge Assembly C±4799±B
Fuel Pressure Test Adapter 6539
Spanner Wrench 6856
Metering Orifice
Fuel Line Adapter 1/4
O2S (Oxygen Sensor) Remover/InstallerÐC-4907
RSFUEL DE

Page 2876 of 4284

CHRYSLER VOYAGER 2001 Service Manual FUEL FILTER
REMOVAL
(1) Release fuel pressure, refer to the Fuel release
procedure in this section.
(2) Disconnect the negative battery cable.
(3) Raise vehicle and support.
(4) Support the fuel tank

Page 2877 of 4284

CHRYSLER VOYAGER 2001 Service Manual (2) Pull off the locking wedge.
(3) Using a small screwdriver lift locking finger
away from terminal and push terminal out of connec-
tor (Fig. 3).
(4) Push level sensor signal and ground terminals
ou

Page 2878 of 4284

CHRYSLER VOYAGER 2001 Service Manual (3) While feeding wires into guide grooves, slide
level sensor up into channel until it snaps into place
(Fig. 8). Ensure tab at bottom of sensor locks in
place.
(4) Install level sensor wires in conn

(3) While feeding wires into guide grooves, slide
level sensor up into channel until it snaps into place
(Fig. 8). Ensure tab at bottom of sensor locks in
place.
(4) Install level sensor wires in connector. Push
the wires up through the connector and then pull
them down until they lock in place. Ensure signal
and ground wires are installed in the correct posi-
tion.
(5) Install locking wedge on connector.
(6) Push connector up into bottom of fuel pump
module electrical connector.
(7) Install fuel pump module. Refer to Fuel Pump
Module in this section.
FUEL LINES
DESCRIPTION - FUEL LINES/HOSES AND
CLAMPS
Also refer to Quick-Connect Fittings.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRES-
SURE MUST BE RELEASED. REFER TO THE FUEL
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP.
The lines/tubes/hoses used on fuel injected vehicles
are of a special construction. This is due to the
higher fuel pressures and the possibility of contami-
nated fuel in this system. If it is necessary to replace
these lines/tubes/hoses, only those marked EFM/EFI
may be used.If equipped:The hose clamps used to secure rub-
ber hoses on fuel injected vehicles are of a special
rolled edge construction. This construction 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 high-pressure fuel leaks.
Use new original equipment type hose clamps.
STANDARD PROCEDURES - HOSES AND
CLAMPS
Inspect all hose connections (clamps and quick con-
nect fittings) for completeness and leaks. Replace
cracked, scuffed, or swelled hoses. Replace hoses that
rub against other vehicle components or show sign of
wear.
Fuel injected vehicles use specially constructed
hoses. When replacing hoses, only use hoses marked
EFM/EFI.
When installing hoses, ensure that 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 edges 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
N´m (10 in. lbs.) torque.
Inspect all hose connections such as clamps, cou-
plings and fittings to make sure they are secure and
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.
Replace as necessary.
Avoid contact of any fuel tubes/hoses with other
vehicle components that could cause abrasions or
scuffing. Be sure that the plastic fuel lines/tubes are
properly routed to prevent pinching and to avoid heat
sources.
FUEL PRESSURE REGULATOR
OPERATION
The fuel system uses a nonadjustable pressure reg-
ulator that maintains fuel system pressure at
approximately 400634 kPa (5865 psi). The fuel
pressure regulator contains a diaphragm, calibrated
spring and a fuel return valve. The spring pushes
down on the diaphragm and closes off the fuel return
port. System fuel pressure reflects the amount of fuel
pressure required to open the return port.
Fig. 8 Installation Channel
1 - CHANNEL FOR LEVEL SENSOR
2 - PUMP MODULE
14 - 6 FUEL DELIVERYRS
FUEL LEVEL SENDING UNIT / SENSOR (Continued)

Page 2879 of 4284

CHRYSLER VOYAGER 2001 Service Manual The pressure regulator is a mechanical device that
is NOT controlled by the PCM or engine vacuum.
REMOVAL
The fuel pressure regulator is part of the fuel
pump module (Fig. 9). Remove the fuel pump mod

The pressure regulator is a mechanical device that
is NOT controlled by the PCM or engine vacuum.
REMOVAL
The fuel pressure regulator is part of the fuel
pump module (Fig. 9). Remove the fuel pump module
from the fuel tank to access the fuel pressure regula-
tor. Refer to the Fuel Pump Module removal in this
section.
(1) Spread tangs on pressure regulator retainer.
(2) Pry fuel pressure regulator out of housing.
(3) Ensure both upper and lower O-rings were
removed with regulator.
INSTALLATION
The fuel pressure regulator is part of the fuel
pump module. Remove the fuel pump module from
the fuel tank to access the fuel pressure regulator.
Refer to the Fuel Pump Module removal in this sec-
tion.
(1)
Lightly lubricate the O-rings with clean engine oil
and place them into opening in pump module (Fig. 9).
(2) Push regulator into opening in pump module.
(3) Fold tangs on regulator retainer over tabs on
housing.
FUEL PUMP
DESCRIPTION
The electric fuel pump is located in and is part of
the fuel pump module. It is a positive displacement,
gerotor type, immersible pump with a permanent
magnet electric motor. The fuel pump module is sus-
pended in fuel in the fuel tank.
OPERATION
The pump draws fuel through a strainer and
pushes it through the motor to the outlet. The pump
contains a check valve. The valve, in the pump out-
let, maintains pump pressure during engine off con-
ditions. The fuel pump relay provides voltage to the
fuel pump. The fuel pump has a maximum dead-
headed pressure output of approximately 880 kPa
(130 psi). The regulator adjusts fuel system pressure
to approximately 400 kpa634 kpa (58 psi65 psi).
FUEL PUMP MODULE
DESCRIPTION
The fuel pump module is installed in the top of the
fuel tank (Fig. 10).
The fuel pump module contains the following:
²Electric fuel pump
²Fuel pump reservoir
²Inlet strainer
²Fuel pressure regulator
²Fuel gauge sending unit
²Fuel supply line connection
The inlet strainer, fuel pressure regulator
and fuel level sensor are the only serviceable
items. If the fuel pump or electrical wiring har-
ness requires service, replace the fuel pump
module.
The electric fuel pump is located in and is part of
the fuel pump module. It is a positive displacement,
gerotor type, immersible pump with a permanent
magnet electric motor.
OPERATION
The pump draws fuel through a strainer and
pushes it through the motor to the outlet. The pump
contains one check valve. The check valve, in the
Fig. 9 Fuel Pressure Regulator O-rings
1 - UPPER O-RING
2 - LOWER 0-RING
Fig. 10 Fuel Pump Module
1 - INLET STRAINER
2 - FUEL RESERVOIR
3 - FUEL PRESSURE REGULATOR
4 - FUEL LEVEL SENSOR
RSFUEL DELIVERY14-7
FUEL PRESSURE REGULATOR (Continued)

Page 2880 of 4284

CHRYSLER VOYAGER 2001 Service Manual pump outlet, maintains pump pressure during engine
off conditions. The fuel pump relay provides voltage
to the fuel pump.
The fuel pump has a maximum deadheaded pres-
sure output of approximately 880

pump outlet, maintains pump pressure during engine
off conditions. The fuel pump relay provides voltage
to the fuel pump.
The fuel pump has a maximum deadheaded pres-
sure output of approximately 880 kPa (130 psi). The
regulator adjusts fuel system pressure to approxi-
mately 400634 kPa (5865 psi).
FUEL PUMP ELECTRICAL CONTROL
Voltage to operate the electric pump is supplied
through the fuel pump relay. For an electrical opera-
tional description of the fuel pump refer to fuel Pump
RelayÐPCM Output.
ELECTRICAL PUMP REPLACEMENT
The electric fuel pump is not serviceable. If the
fuel pump or electrical wiring harness needs replace-
ment, the complete fuel pump module must be
replaced. Perform the Fuel System Pressure Release
procedure before servicing the fuel pump.
REMOVAL
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE.
(1) Remove fuel filler cap and perform Fuel Sys-
tem Pressure Release procedure.
(2) Disconnect negative cable from auxiliary
jumper terminal.
(3) Drain fuel tank, refer to the Fuel Tank proce-
dure in the Fuel Delivery section.
(4) Remove fuel tank, refer to the Fuel Tank
removal section.
(5) Clean top of tank to remove loose dirt and
debris.
(6) Using a brass punch and hammer remove lock-
nut to release pump module (Fig. 11).
WARNING: THE FUEL RESERVOIR OF THE FUEL
PUMP MODULE DOES NOT EMPTY OUT WHEN THE
TANK IS DRAINED. THE FUEL IN THE RESERVOIR
MAY SPILL OUT WHEN THE MODULE IS REMOVED.
(7) Remove fuel pump module and O-ring from
tank (Fig. 12). Discard O-ring.
INSTALLATION
(1) Wipe seal area of tank clean and place a new
O-ring seal in position on pump.
(2) Position fuel pump module in tank.
(3) Tighten locknut using a brass punch and ham-
mer to install the locknut (Fig. 11).
(4) Install fuel tank, refer to the Fuel Tank instal-
lation section.(5) Lower vehicle.
(6) Connect negative cable battery.
(7) Fill fuel tank. Check for leaks.
(8) Install fuel filler cap.
Fig. 11 FUEL PUMP MODULE LOCKING RING
Fig. 12 Fuel Pump Module Removal
1 - FUEL PUMP MODULE
2 - O-RING
14 - 8 FUEL DELIVERYRS
FUEL PUMP MODULE (Continued)

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