Chrysler Caravan/Voyager/Town and Country 1996-1999

Fuel Rail (Charging) Assembly

Print

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.

2.4L Engine

See Figures 1, 2, 3, 4 and 5



Click image to see an enlarged view

Fig. Fig. 1: Remove the vacuum line from the intake manifold



Click image to see an enlarged view

Fig. Fig. 2: Disconnect and label the electrical and vacuum connections



Click image to see an enlarged view

Fig. Fig. 3: Disengage the MAP sensor connector



Click image to see an enlarged view

Fig. Fig. 4: Disconnect the fuel line fitting



Click image to see an enlarged view

Fig. Fig. 5: Remove the intake manifold screws

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Disconnect the air inlet hose from the throttle body.
  6.  
  7. Disconnect the throttle cable and speed control cable (if equipped), from the throttle lever.
  8.  
  9. Compress the throttle cable retaining tabs and remove the throttle cables from the throttle bracket.
  10.  
  11. Disengage the electrical connectors from the Throttle Position Sensor (TPS) and Idle Air Control (IAC) motor.
  12.  
  13. Disconnect vacuum hoses from the fittings on the intake plenum.
  14.  
  15. Disengage electrical connectors from the Intake Air Temperature (IAT) sensor and MAP sensor.
  16.  
  17. Disconnect the fuel supply line from the fuel rail. This is a quick connect fitting. Squeeze the fitting retainer tabs together and pull the quick connect fitting assembly apart.
  18.  


CAUTION
Wrap shop towels around the hose connection to catch any gasoline spillage.

  1. Remove the bolt securing the bottom of the intake support bracket.
  2.  
  3. Remove the intake manifold mounting screws.
  4.  
  5. Disconnect the fuel injector electrical connectors.
  6.  
  7. Remove the fuel rail attaching screws.
  8.  
  9. Lift the fuel rail/injector assembly off the intake manifold. Be careful not to damage the injector O-rings during the removal from their ports. If they are damaged, replace them as necessary. Cover the fuel injector openings in the intake manifold.
  10.  

To install:
  1. Ensure that the fuel injector holes are clean.
  2.  
  3. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
  4.  
  5. Insert the fuel injector nozzles into the openings in the intake manifold. Seat the injectors and tighten the fuel rail mounting screws to 16 ft. lbs. (22 Nm).
  6.  
  7. Reconnect the electrical connectors to the fuel injectors.
  8.  
  9. Install a new intake manifold gasket and position the intake manifold onto the engine.
  10.  
  11. Tighten the intake manifold mounting bolts, starting at the center of the manifold and working outward in both directions. Torque the mounting bolts to 17 ft. lbs. (23 Nm).
  12.  
  13. Lightly oil the tube end, then reconnect the fuel supply line quick connect fitting to the fuel rail. Be sure the quick connect fittings are fully engaged.
  14.  
  15. Install and tighten bolt that secures the bottom of the intake support bracket.
  16.  
  17. Attach the IAT sensor and MAP sensor electrical connectors.
  18.  
  19. Reconnect the vacuum lines to the intake plenum fittings.
  20.  
  21. Attach the IAC motor and TPS electrical connectors.
  22.  
  23. Secure the throttle cables into the cable bracket by engaging the retaining tabs.
  24.  
  25. Reconnect the throttle cable and speed control cable (if equipped) to the throttle lever.
  26.  
  27. Connect the air cleaner inlet hose to the throttle body.
  28.  
  29. Reconnect negative battery cable.
  30.  


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 6, 7, 8, 9, 10 and 11



Click image to see an enlarged view

Fig. Fig. 6: Remove the air intake plenum-to-lower intake manifold mounting bolts



Click image to see an enlarged view

Fig. Fig. 7: Remove the air intake plenum (upper intake manifold)



Click image to see an enlarged view

Fig. Fig. 8: Disconnect the fuel injector wiring harness from the engine wiring harness.



Click image to see an enlarged view

Fig. Fig. 9: After removing the upper intake manifold, cover the openings to prevent any dirt from entering



Click image to see an enlarged view

Fig. Fig. 10: Remove the fuel rail retaining bolts ...



Click image to see an enlarged view

Fig. Fig. 11: ... then lift the fuel rail/injector assembly off the intake manifold. Be careful not to damage the fuel injector O-rings

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 air inlet resonator assembly.
  6.  
  7. Remove the throttle cable.
  8.  
  9. Label and disengage the electrical connectors from the Idle Air Control (IAC) motor, Throttle Position Sensor (TPS) and Engine Coolant Temperature (ECT) sensor.
  10.  
  11. Label and disconnect the vacuum harness from the throttle body and the vacuum hoses from the air intake plenum.
  12.  
  13. Place a shop towel under the fuel hose connection to absorb any spilled fuel and disconnect the fuel hose from the fuel rail.
  14.  
  15. Disconnect the fuel injector wiring harness from the engine wiring harness.
  16.  
  17. Remove the intake plenum-to-intake manifold retaining bolts. Remove the ignition coil.
  18.  
  19. Remove the air intake plenum. Cover the the intake manifold to prevent the entrance of dirt or other foreign material.
  20.  
  21. Disconnect the fuel injector wiring harness from the engine wiring harness.
  22.  
  23. Remove the fuel rail retaining bolts. Lift the fuel rail/injector assembly off the intake manifold. Be careful not to damage the fuel injector O-rings.
  24.  
  25. Inspect the injector O-rings for damage and replace, as necessary.
  26.  

To install:
  1. Make sure the injectors are fully seated in the fuel rail and the clips are securely in place. Make sure the injector holes in the manifold are clean.
  2.  
  3. Lubricate the lower injector O-rings with clean engine oil. Start each injector into its hole and push the assembly into place until all injectors are fully seated.
  4.  
  5. Install the fuel rail retaining bolts and tighten to 115 inch lbs. (13 Nm).
  6.  
  7. Install the fuel supply and return tube hold-down bolt and the vacuum crossover tube hold-down bolt and tighten to 95 inch lbs. (10 Nm).
  8.  
  9. Attach the electrical connectors to the fuel injectors in correct order. Connect the fuel injector wiring harness to the engine harness.
  10.  
  11. Clean the intake manifold mating surfaces. Place the manifold gaskets, beaded sealer side up, on the lower manifold.
  12.  
  13. Place the air intake plenum in position and install the ignition coil. Install the retaining bolts and tighten to 115 inch lbs. (13 Nm).
  14.  
  15. Connect the fuel line to the fuel rail. Connect the vacuum line to the intake plenum.
  16.  
  17. Attach the electrical connectors to the ECT sensor, TPS and IAC motor.
  18.  
  19. Reconnect the PCV and power brake booster supply hose to the intake manifold.
  20.  
  21. Reconnect the vacuum vapor harness to the throttle body.
  22.  
  23. Install the throttle cable. Install the air inlet resonator.
  24.  
  25. Reconnect the negative battery cable.
  26.  

  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.  

3.3L and 3.8L Engines

See Figures 12, 13 and 14



Click image to see an enlarged view

Fig. Fig. 12: Remove the intake manifold mounting bolts



Click image to see an enlarged view

Fig. Fig. 13: Remove the fuel rail retaining bolts



Click image to see an enlarged view

Fig. Fig. 14: Remove the fuel rail assembly

The engines use 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 intake manifold cover.
  6.  
  7. Remove the air inlet resonator.
  8.  
  9. Disconnect the throttle cable and speed control cable (if equipped) from the throttle lever and cable bracket.
  10.  
  11. Disengage the Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) electrical connectors. Tag and disconnect the vacuum hose harness from the throttle body and intake manifold.
  12.  
  13. Remove the EGR tube-to-intake manifold flange bolts.
  14.  
  15. Remove the cylinder head-to-intake plenum strut.
  16.  
  17. Disengage the electrical connector from the Manifold Absolute Pressure (MAP) sensor. Remove the engine mounted ground strap.
  18.  
  19. Place a shop towel under the fuel lines to catch any gasoline spillage. Disconnect the fuel line from the chassis tube by squeezing the retainer tabs together and pulling the quick-connect fitting off the fuel tube nipple.
  20.  
  21. Remove the Direct Ignition System (DIS) coils and alternator bracket-to-intake manifold bolt.
  22.  
  23. Remove the intake manifold mounting bolts and rotate the manifold back over the rear valve cover. Cover the the intake manifold to prevent the entrance of dirt or other foreign material.
  24.  
  25. Remove the screws from the fuel tube clamp and fuel rail retaining bolts. Spread the retainer bracket to allow fuel tube removal clearance.
  26.  
  27. Disconnect the fuel injector wiring connector from the fuel injector.
  28.  
  29. Disconnect the Camshaft Position (CMP) sensor and Engine Coolant Temperature (ECT) sensor. Remove the fuel rail.
  30.  
  31. Check the injector O-rings for damage and replace, as necessary.
  32.  

To install:
  1. Make sure the injectors are fully seated in the fuel rail and the clips are securely in place. Make sure the injector holes in the manifold are clean.
  2.  
  3. Lubricate the injector O-rings with clean engine oil. Install the tip of each fuel injector into their ports and push the assembly into place until fully seated.
  4.  
  5. Install the fuel rail mounting bolts and tighten to 16 ft. lbs. (22 Nm).
  6.  
  7. Install the fuel tube retaining bracket screw and tighten to 35 inch lbs. (4 Nm).
  8.  
  9. Reconnect the fuel injector wiring.
  10.  
  11. Attach the electrical connectors to the CMP and ECT sensors.
  12.  
  13. Remove the covering on the lower intake manifold and clean the mounting surface.
  14.  
  15. Install the intake manifold gasket onto the lower manifold and install the upper manifold. Hand tighten the bolts only.
  16.  
  17. Install the alternator bracket-to-intake manifold bolt and cylinder head-to-intake manifold strut bolts. Do not tighten.
  18.  
  19. Tighten the manifold bolts, in sequence, to 21 ft. lbs. (28 Nm).
  20.  
  21. Tighten the alternator bracket-to-intake manifold bolt to 40 ft. lbs. (54 Nm).
  22.  
  23. Tighten the cylinder head-to-intake manifold strut bolts to 40 ft. lbs. (54 Nm).
  24.  
  25. Attach the ground strap and MAP sensor electrical connector.
  26.  
  27. Connect the vacuum harness to the intake plenum. Connect the PCV hoses.
  28.  
  29. Install a new gasket and connect the EGR tube to the intake manifold plenum. Tighten the bolts to 16 ft. lbs. (22 Nm).
  30.  
  31. Connect the electrical connector to the TPS and IAC motor. Connect the vacuum harness to the throttle body.
  32.  
  33. Install the ignition coils and tighten the retainers to 105 inch lbs. (12 Nm).
  34.  
  35. Install the fuel hose quick-connect fittings to the chassis tubes. Push the fittings onto the tubes until they click in place. Pull on the fittings to ensure complete insertion.
  36.  
  37. Install the throttle cable and speed control cable, if equipped.
  38.  
  39. Install the air inlet resonator.
  40.  
  41. Reconnect the negative battery cable.
  42.  

  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.  

 
label.common.footer.alt.autozoneLogo