Chrysler Caravan/Voyager/Town and Country 1996-1999

Fuel Injector

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REMOVAL & INSTALLATION




CAUTION
Fuel injection systems remain under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

Except 3.0L Engine

See Figures 1 and 2

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the fuel rail/injector assembly from the vehicle.
  6.  
  7. Position the fuel rail/injector assembly on a work bench or other working area that allows for easy access to the fuel injectors.
  8.  
  9. Rotate the fuel injector and pull the injector out of the fuel rail. The retaining clip will stay on the fuel injector.
  10.  
  11. Inspect the fuel injector O-ring for damage and replace, if necessary. If the injector is being reinstalled, place a protective cap over the injector tip to prevent damage.
  12.  



Click image to see an enlarged view

Fig. Fig. 1: Fuel injector type with retaining clip



Click image to see an enlarged view

Fig. Fig. 2: Fuel injector type with locking slot retainer

  1. Inspect the injector retaining clip and replace, if damaged.
  2.  
  3. Repeat for remaining injectors.
  4.  

To install:
  1. Before installing the injector into the fuel rail assembly, apply a light coating of clean engine oil to the O-ring on the fuel rail end of each injector. This will aid in the installation process.
  2.  
  3. Install the injector clip by sliding the open end into the top slot of the fuel injector. The edge of the reciever cup will slide into the side slots of the clip.
  4.  
  5. Install the injector top end into the reciever cap of the fuel rail. Be careful not to damage the fuel injector O-ring during installation.
  6.  
  7. Repeat for remaining injectors.
  8.  
  9. Install the fuel rail/injector assembly onto the engine.
  10.  
  11. Reconnect negative battery cable.
  12.  


WARNING
When using the ASD Fuel System Test, the ASD relay and fuel pump relay remain energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the OFF position.

  1. Turn the ignition key to the ON position and access the DRB scan tool ASD Fuel System Test to pressurize the fuel system. Check the fuel system for leaks.
  2.  

3.0L Engine

See Figures 1 and 2

The engine uses a sequential Multi-Port Electronic Fuel Injection (MPI) system. The MPI system uses fuel injectors positioned in the intake manifold with the nozzle ends directly above the intake port. The fuel rail assembly must be removed to service the injectors. The system pressure is approximately 48 psi. (330 Kpa). Perform the fuel pressure release procedure before attempting to service the fuel injectors.

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the fuel rail/injector assembly from the vehicle.
  6.  
  7. Position the fuel rail/injector assembly on a work bench or other working area that allows for easy access to the fuel injectors.
  8.  
  9. Remove the fuel injector retaining clip.
  10.  
  11. Remove the injector from the fuel rail by pulling the injector straight out of the fuel rail reciever cup.
  12.  
  13. Inspect the injector O-rings for damage and replace, as necessary. If the injector is being reinstalled, place a protective cap over the injector tip to prevent damage.
  14.  
  15. Inspect the injector retaining clip and replace, if damaged.
  16.  
  17. Repeat for remaining injectors.
  18.  

To install:
  1. Before installing the injector into the fuel rail assembly, apply a light coating of clean engine oil to the O-ring on the fuel rail end of each injector. This will aid in the installation process.
  2.  
  3. Install the injector top end into the reciever cap of the fuel rail. Be careful not to damage the fuel injector O-ring during installation.
  4.  
  5. Install the injector clip by sliding the open end into the top slot of the fuel injector. The edge of the reciever cup will slide into the side slots of the clip.
  6.  
  7. Repeat for remaining injectors.
  8.  
  9. Install the fuel rail/injector assembly onto the engine.
  10.  
  11. Reconnect negative battery cable.
  12.  

  1. Turn the ignition key to the ON position and access the DRB scan tool ASD Fuel System Test to pressurize the fuel system. Check the fuel system for leaks.
  2.  

TESTING



  1. Unplug the injector electrical connector.
  2.  
  3. Using an ohmmeter, test the injector resistance across the injector terminals. The reading should be approximately 12 ohms at 68°F (20°C).
    1. If the resistance falls outside specifications, replace the faulty injector.
    2.  
    3. If the resistance is within specifications, proceed with the testing.
    4.  

  4.  
  5. Place a 12 volt test lamp across the injector's electrical connector terminals. Watch the test lamp while cranking the engine and compare with the following:
    1. If the test lamp does not flash, check the power feed and ground circuits between the PCM and the injector connector. Refer to the wiring diagrams in Chassis Electrical for wire colors. If the circuits are faulty, repair them. If the circuits are OK, test the engine control system using the Chrysler DRB, or equivalent scan tool.
    2.  
    3. If the test lamp flashes, proceed with the testing.
    4.  

  6.  
  7. Check for fuel delivery at the suspect injector by removing the injector from the fuel rail and check for fuel and/or restrictions in the rail or injector fuel inlet. Compare your results with the following:
    1. If there is no fuel present at the injector, replace the plugged injector, or clean the restricted passage, as necessary.
    2.  
    3. If there is fuel present at the injector, proceed with the testing.
    4.  

  8.  
  9. With the injector removed from the fuel rail, connect a 12 volt source to one terminal on the injector connector and a ground wire to the other terminal. The injector should click each time the ground wire is connected and disconnected to and from the terminal.
  10.  
  11. If the injector clicks, it is OK. If it does not click, it must be replaced.
  12.  

 
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