Chrysler Caravan/Voyager/Town and Country 1996-1999

Relieving Fuel System Pressure

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RELIEVING




CAUTION
The fuel injection system remains 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 may result in fire and/or personal injury.

2.4L, 3.3L and 3.8L Engines

See Figures 1, 2 and 3

The following procedure requires fuel pressure release hose C-4799-1 or equivalent. Fuel gauge C-4799-B contains a hose to direct fuel into an approved container.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the fuel tank filler cap to release the pressure in the fuel tank.
  4.  



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Fig. Fig. 1: Fuel pressure test port location-2.4L engine



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Fig. Fig. 2: Fuel pressure test port location-3.3L and 3.8L engines

  1. Remove the cap from the fuel pressure test port on the fuel rail.
  2.  


CAUTION
Always wear proper eye protection when relieving fuel system pressure. Do not allow fuel to spill on the intake or exhaust manifolds. Place shop towels under and around the pressure test port to absorb fuel when the pressure is released from the fuel rail.



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Fig. Fig. 3: Releasing the fuel system pressure

  1. Place the open end of fuel pressure release hose tool No. C-4799-1, or equivalent, into an approved gasoline container. Place a shop towel under the test port.
  2.  
  3. Connect the other end of the hose onto the fuel pressure test port, to relieve the system pressure.
  4.  
  5. After the fuel pressure has been released, remove the hose from the test port and install the cap.
  6.  

3.0L Engine
  1. Remove the fuel pump relay from the Power Distribution Center (PDC) located on the left side in the engine compartment. Location of the relay can be verified by the label located on the underside of the PDC cover.
  2.  
  3. Start the engine and allow it to run until it stalls.
  4.  
  5. Continue to start the engine until it will no longer run.
  6.  
  7. Turn the ignition key to the OFF position.
  8.  


WARNING
Steps 1-4 must be performed to relieve the pressurized fuel from within the fuel rail. Do NOT use the following steps to relieve this fuel pressure, as excessive fuel will be forced into a cylinder chamber.

  1. Disconnect any fuel injector.
  2.  
  3. Connect one end of a jumper wire (18 gauge or smaller) to either injector terminal of the fuel injector harness connector (black connector located on fuel rail harness). Connect the other end of the jumper wire to the positive battery terminal.
  4.  
  5. Connect one end of a second jumper wire to the remaining (other) injector terminal.
  6.  


WARNING
Do NOT supply power to the injector for more than four seconds or permanent damage to the injector will result.

  1. Momentarily touch the other end of the second jumper wire to the negative battery terminal for no more than four seconds .
  2.  

  1. Place a shop rag or towel under the fuel line at the quick-disconnect fitting to the fuel rail.
  2.  
  3. Disconnect the negative battery cable. Squeeze the quick-disconnect fitting retainer tabs together and pull the fuel tube/quick-disconnect fitting assembly off the fuel tube nipple. The retainer will remain on the fuel tube.
  4.  
  5. Install the fuel pump relay into the PDC.
  6.  
  7. One or more Diagnostic Trouble Codes (DTC's) may have been stored in the PCM memory due to the removal of the fuel pump relay. Chrysler's Diagnostic Readout Box (DRB), or equivalent scan tool must be used to erase any DTC's.
  8.  

 
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