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Home >> Chrysler >> 2001 >> Sebring LX, 2D Convertible >> Repair and Diagnosis >> External Pages >> Different car >> Section 36 (Fuel Supply System - Coupe) >> Fuel Supply >> Fuel Supply Diagnosis >> Symptom Procedures >> INSPECTION PROCEDURE 1: Engine Malfunctions Due to Insufficient Fuel Supply >> Diagnosis

INSPECTION PROCEDURE 1: Engine Malfunctions Due to Insufficient Fuel Supply: Diagnosis

WARNING: This page is about a different car, the 2005 Dodge Stratus and 2005 Chrysler Sebring. However, it is still accessible from the selected car via links, so may be relevant.

Required Special Tools: 

  1. STEP 1. Using scan tool MB991502, read the diagnostic trouble code (DTC). 
    CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502.
    1. Connect scan tool MB991502 to the data link connector.
    2. Turn the ignition switch to the "ON" position.
    3. Read the DTC.
    4. Turn the ignition switch to the "LOCK" (OFF) position.

    Q: Is the DTC set? 

    YES  : Refer to, Diagnostic Trouble Code Chart < 2.4L ENGINE > (Refer to FAIL-SAFE FUNCTION REFERENCE TABLE ) < 3.0L ENGINE > or (Refer to FAIL-SAFE FUNCTION REFERENCE TABLE ).

    NO:  Go to Step 2.

    Fig 1: Connecting Scan Tool To Data Link Connector
    G04545366Courtesy of DAIMLERCHRYSLER CORPORATION
  2. STEP 2. Check the fuel pressure. 
    WARNING: To prevent a fire, cover the hose connection with shop towels to prevent splashing of fuel that could be caused by some residual pressure in the fuel pipe line.
    1. Release residual pressure from the fuel line to prevent fuel spray. < 2.4L ENGINE > (Refer to On-Vehicle Service - FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE PRESSURIZED FUEL LINES) ) or < 3.0L ENGINE > (Refer to On-Vehicle Service - FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE PRESSURIZED FUEL LINES) ).
    2. Disconnect the fuel high-pressure hose at the fuel rail side.
    3. Assemble the fuel pressure measurement tools as follows.
      Fig 2: Disconnecting Fuel High-Pressure Hose At Fuel Rail Side
      G04545367Courtesy of DAIMLERCHRYSLER CORPORATION
    4. When using a fuel pressure gauge.
      1. Remove the union joint and bolt from special tool MD998709 (adaptor hose) and instead attach special tool MD998742 (hose adaptor) to the adaptor hose.
      2. Place a suitable O-ring or gasket on assembled special tools MD998709 and MD998742 and install the fuel pressure gauge.
      3. Install the assembled fuel pressure measurement tool between the fuel rail and fuel high-pressure hose.
        Fig 3: Identifying Fuel Pressure Gauge Components
        G04545368Courtesy of DAIMLERCHRYSLER CORPORATION
    5. When using special tool MB991637 (fuel pressure gauge set).
      1. Remove the union joint and bolt from special tool MD998709 (adaptor hose) and instead attach special tool MD998742 (hose adaptor) to the adaptor hose.
      2. Install special tool MB991637 (fuel pressure gauge set) to assembled special tools MD998709 and MD998742 via a gasket.
      3. Install the assembled fuel pressure measurement tool between the fuel rail and the fuel high-pressure hose.
        Fig 4: Identifying Fuel Pressure Gauge Set Components
        G04545369Courtesy of DAIMLERCHRYSLER CORPORATION
        CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502.
    6. Connect scan tool MB991502 to the data link connector.
    7. Use the Actuator test 07 to drive the fuel pump. Check that there is no fuel leaking from any section when the fuel pump is operating.
    8. Stop the fuel pump.
    9. Start the engine and run at idle.
    10. Measure fuel pressure while the engine is running at idle.

      Standard value: Approximately 270 kPa (38 psi) at curb idle 

      Fig 5: Connecting Scan Tool To Data Link Connector
      G04545370Courtesy of DAIMLERCHRYSLER CORPORATION
    11. Disconnect the vacuum hose from the fuel pressure regulator and measure fuel pressure with the hose end closed with your finger.

      Standard value: 330 - 350 kPa (47 - 50 psi) at curb idle 

    12. Check to see that fuel pressure at idle does not drop even after the engine has been revved several times.
    13. Revving the engine repeatedly, hold the fuel return hose lightly with your fingers to feel that fuel pressure is present in the return hose.
      NOTE: If the fuel flow rate is low, there will be no fuel pressure in the return hose.
    14. If any of fuel pressure measured in Steps  10 to  13 is out of specification, troubleshoot and repair according to the table below.
      Fig 6: Holding Fuel Return Hose With Fingers
      G04545371Courtesy of DAIMLERCHRYSLER CORPORATION
      SYMPTOM & REMEDY

      SYMPTOM PROBABLE CAUSE REMEDY
      • Fuel pressure too low
      • Fuel pressure drops after revving
      • No fuel pressure in fuel return hose
      		 Clogged fuel filter Replace fuel filter
      Fuel leaking to return side due to poor fuel regulator valve seating or settled spring Replace fuel pressure regulator
      Low fuel pump delivery pressure Replace fuel pump
      Fuel pressure too high Binding valve in fuel pressure regulator Replace fuel pressure regulator
      Clogged fuel return hose or pipe Clean or replace hose or pipe
      Fuel pressure is unchanged when vacuum hose is connected and when disconnected Damaged vacuum hose or clogged nipple Replace vacuum hose or clean nipple
      Defective fuel pressure regulator Replace fuel pressure regulator
    15. Stop the engine and observe fuel pressure gauge reading. It is normal if the reading does not drop within two minutes. If it does, observe the rate of drop and troubleshoot and repair according to the table below. Start, then stop the engine.
      1. Squeeze the fuel return line closed to confirm leak-down occurs from defective fuel pressure regulator.
      2. Squeeze the fuel supply line closed to confirm leak-down occurs from defective fuel pump check valve.
      3. If pressure continues to drop with both fuel lines squeezed closed, injector(s) are leaking.
        SYMPTOM & REMEDY

        SYMPTOM PROBABLE CAUSE REMEDY
        Fuel pressure drops gradually after engine is stopped Leaky injector Replace injector
        Leaky fuel regulator valve seat Replace fuel pressure regulator
        Fuel pressure drops sharply immediately after engine is stopped Check valve in fuel pump is held open Replace fuel pump
    16. Release residual pressure from the fuel pipe line. < 2.4L ENGINE > (Refer to On-Vehicle Service - FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE PRESSURIZED FUEL LINES) ) or < 3.0L ENGINE > (Refer to On-Vehicle Service - FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE PRESSURIZED FUEL LINES) ).
      WARNING: Cover the hose connection with shop towels to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line.
    17. Remove the fuel pressure gauge or special tool MB991637, and special tools MD998709 and MD998742 from the fuel rail.
    18. Replace the O-ring at the end of the fuel high-pressure hose with a new one.
    19. Fit the fuel high-pressure hose into the fuel rail and tighten the bolts to specified torque.

      Tightening torque: 4.9 +/- 1.0 N.m (44 +/- 8 in-lb) 

      Fig 7: Removing Fuel Pressure Gauge Or Special Tool From Fuel Rail
      G04545372Courtesy of DAIMLERCHRYSLER CORPORATION
    20. Check for fuel leaks.
      1. Use scan tool MB991502 to operate the fuel pump.
      2. Check the fuel line for leaks, and repair as needed.
    21. Disconnect scan tool MB991502.

    Q: Are the fuel pressure test in good condition? 

    YES  : Go to  Step 5.

    NO:  Repair or replace. Then go to Step 3.

  3. STEP 3. Check for bending, twisting or clogging of the fuel pipe or hose. 

    Q: Are the fuel pipe and hose in good condition? 

    YES  : Go to Step 4.

    NO:  Repair or replace a defective pipe or hose. Then go to  Step 6.

    Fig 8: Checking Fuel Pipe/Hose For Hose Bending, Twisting Or Clogging
    G04545373Courtesy of DAIMLERCHRYSLER CORPORATION
  4. STEP 4. Check the fuel pump module operation. 
    CAUTION:
    • To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502.
    • To prevent not to confuse top and bottom of fuel pump relay harness side connector, ensure the triangular mark on the junction block and check the connector.
    1. Check the operating of the fuel pump by using scan tool MB991502 to force-drive the fuel pump.
    2. If the fuel pump will not operate, check by using the following procedure. If normal, check the fuel pump drive circuit.
      Fig 9: Connecting Scan Tool To Data Link Connector
      G04545374Courtesy of DAIMLERCHRYSLER CORPORATION
      1. Turn the ignition switch to the "LOCK" (OFF) position.
      2. Remove the instrument panel side cover (driver's side).
      3. Remove the fuel pump relay (2), and apply battery voltage to junction block side connector terminal number 4. Check that an operating sound can be heard from the fuel pump.
        NOTE: As the fuel pump is an in-tank type, the fuel pump sound is hard to hear. Remove the fuel tank filler tube cap and check from the tank inlet.
      4. Check for fuel pressure by pinching the fuel hose with fingertips.
      5. Install the fuel pump relay (2) and instrument panel side cover (driver's side).

    Q: Does the fuel pump module work normally? 

    YES  : Then go to Step 5.

    NO:  Replace the module. Then go to  Step 6.

    Fig 10: Checking Fuel Pump Module Operation
    G04545375Courtesy of DAIMLERCHRYSLER CORPORATION
  5. STEP 5. Check the inside of the fuel tank for contamination and rust. 
    1. Drain the fuel.
    2. Remove the fuel tank. (Refer to FUEL TANK .)

    Q: Is the fuel tank in good condition? 

    YES  : Go to Step 6.

    NO:  Replace the fuel filter, and clean the fuel tank and fuel line. Then go to Step 6.

  6. STEP 6. Retest the system. 

    Q: Is the engine malfunction eliminated? 

    YES  : The procedure is complete.

    NO:  Return to  Step 1.

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