Chrysler Caravan/Voyager/Town n Country 1984-1995

Fuel Injector Rail Assembly

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REMOVAL & INSTALLATION



2.5L Turbocharged Engines

See Figures 1, 2, 3, 4, 5 and 6



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Fig. Fig. 1: Throttle body and air cleaner assembly-2.5L turbocharged engines



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Fig. Fig. 2: Fuel hoses and electrical connections-2.5L engines



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Fig. Fig. 3: PCV and vacuum vapor harness connections



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Fig. Fig. 4: Fuel hoses and electrical connections



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Fig. Fig. 5: Detonation (knock sensor) and PCV vacuum nipple



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Fig. Fig. 6: Fuel rail and injector assembly

  1. Perform fuel system pressure release procedure.
  2.  
  3. Disconnect negative battery cable.
  4.  
  5. Remove air cleaner assembly.
  6.  
  7. Disconnect detonation (knock) sensor and fuel injector wiring connectors.
  8.  
  9. Loosen fuel supply hose clamp at fuel rail inlet and remove hose. Wrap a shop towel around hose to absorb any fuel spillage which may occur when removing.
  10.  
  11. Loosen fuel return hose clamp at the fuel pressure regulator and remove the hose. Wrap a shop towel around the hose to absorb any fuel spillage, which may occur when removing the hose.
  12.  
  13. Disconnect the vacuum hose from the fuel pressure regulator.
  14.  
  15. Remove the fuel pressure regulator mounting bolts from the fuel rail.
  16.  
  17. Remove the fuel pressure regulator from the fuel rail.
  18.  
  19. Remove the PCV vacuum harness and vacuum vapor harness from the intake manifold.
  20.  
  21. Remove the fuel rail to the valve cover bracket screw. Remove the knock sensor connector from the sensor.
  22.  
  23. Remove the fuel rail to intake manifold mounting bolts.
  24.  
  25. Remove fuel rail and injector assembly by pulling rail so that injectors come straight out of there ports.
  26.  
  27. Be careful not to damage rubber injector O-ring upon removal from ports.
  28.  
  29. Remove fuel rail assembly from vehicle.
  30.  
  31. Do not remove fuel injectors until fuel rail assembly has been completely removed from vehicle.
  32.  

To install:
  1. Be sure injectors are seated into receiver cup, with lockring in place.
  2.  
  3. Install injector wiring harness to injectors and fasten into wiring clips.
  4.  
  5. Make sure injector holes are clean and all plugs have been removed.
  6.  
  7. Lubricate injector O-ring with a drop of clean engine oil to ease installation.
  8.  
  9. Put tip of each injector into respective ports. Push assembly into place until injectors are seated in ports.
  10.  
  11. Install attaching bolts and ground eyelet. Tighten bolts to 21 ft. lbs. (28 Nm).
  12.  
  13. Engage detonation (knock) sensor wire connector to sensor. Install fuel rail-to-valve cover bracket screw.
  14.  
  15. Lubricate fuel pressure O-ring with a drop of clean engine oil and install into receiver cup on fuel rail.
  16.  
  17. Install attaching nuts and tighten to 65 inch lbs. (7 Nm).
  18.  
  19. Install the PCV system hose harness and vacuum hose harness.
  20.  
  21. Reconnect vacuum hose from fuel pressure regulator.
  22.  
  23. Connect fuel return hose to fuel pressure regulator; tighten hose clamp.
  24.  
  25. Connect fuel supply hose to fuel rail inlet and tighten hose clamp.
  26.  
  27. Engage fuel injector and detonation (knock) sensor wiring connector.
  28.  
  29. Install air cleaner assembly.
  30.  
  31. Connect negative battery cable.
  32.  
  33. Check the system for leaks.
  34.  

3.0L Engines

See Figures 7 and 8



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Fig. Fig. 7: Removing the air intake plenum-3.0L engines



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Fig. Fig. 8: Fuel rail assembly

  1. Perform fuel system pressure release procedure.
  2.  
  3. Disconnect negative battery cable.
  4.  
  5. Remove air cleaner-to-throttle body hose.
  6.  
  7. Remove throttle cable and transaxle kickdown linkage.
  8.  
  9. Remove Automatic Idle Speed (AIS) motor and Throttle Position Sensor (TPS) wiring connectors from throttle body.
  10.  
  11. Remove vacuum hose harness from throttle body.
  12.  
  13. Remove PCV and brake booster hoses from air intake plenum.
  14.  
  15. If equipped, remove EGR tube flange from intake plenum.
  16.  
  17. Remove wiring connectors from charge temperature sensor and coolant temperature sensor.
  18.  
  19. Remove vacuum connections from air intake plenum vacuum connector.
  20.  
  21. Remove fuel hoses from fuel rail. Wrap a shop towel around hose to absorb any fuel spillage which may occur when removing.
  22.  
  23. Remove fasteners from air intake plenum to intake manifold.
  24.  
  25. Remove air intake plenum.
  26.  
  27. Cover intake manifold with suitable cover when servicing.
  28.  
  29. Remove vacuum hoses from fuel rail and fuel pressure regulator.
  30.  
  31. Disconnect fuel injector wiring harness from engine wiring harness.
  32.  
  33. Remove the fuel pressure regulator attaching bolts. Loosen the hose clamps and remove the fuel pressure regulator from the fuel rail.
  34.  
  35. Remove the fuel rail attaching bolts and lift the fuel rail from the intake manifold.
  36.  
  37. Be careful not to damage the injector ports when removing.
  38.  
  39. Remove the fuel rail assembly from the vehicle.
  40.  
  41. Do not remove the injectors until the fuel rail has been completely removed from the vehicle.
  42.  

To install:
  1. Make sure the injectors are completely seated with the lockring in place.
  2.  
  3. Make sure the injector holes are clean and that all plugs have been removed.
  4.  
  5. Lubricate injector O-ring with a drop of clean engine oil to ease installation.
  6.  
  7. Put tip of each injector into respective ports. Push assembly into place until injectors are seated in ports.
  8.  
  9. Install fuel rail attaching bolts. Tighten bolts to 115 inch lbs. (13 Nm).
  10.  
  11. Install fuel pressure regulator and hose assembly onto fuel rail. Install attaching bolts to intake manifold. Tighten to 77 inch lbs. (8.7 Nm).
  12.  
  13. Install fuel supply and return tube hold-down bolt and vacuum crossover tube hold-down bolt. Tighten to 95 inch lbs. (11 Nm).
  14.  
  15. Tighten fuel pressure regulator hose clamps.
  16.  
  17. Connect fuel injector wiring harness to engine wiring harness.
  18.  
  19. Connect vacuum harness to fuel pressure regulator and fuel rail assembly.
  20.  
  21. Remove covering from lower intake manifold and clean surface.
  22.  
  23. Place intake manifold gaskets, with beaded sealer up, on lower manifold. Put air intake in place. Install attaching fasteners and tighten to 115 inch lbs. (13 Nm).
  24.  
  25. Connect fuel line to fuel rail and tighten.
  26.  
  27. Connect vacuum harness to air intake plenum.
  28.  
  29. Engage charge temperature sensor and coolant temperature sensor electrical connectors to sensors.
  30.  
  31. If equipped, connect EGR tube flange to intake plenum and tighten to 16 ft. lbs. (22 Nm).
  32.  
  33. Connect PCV and brake booster supply hose to intake plenum.
  34.  
  35. Engage the Automatic Idle Speed (AIS) motor and Throttle Position Sensor (TPS) electrical connectors.
  36.  
  37. Connect vacuum vapor harness to throttle body.
  38.  
  39. Install throttle cable and transaxle kickdown linkage.
  40.  
  41. Install air inlet hose assembly.
  42.  
  43. Connect negative battery cable.
  44.  
  45. Start the vehicle and check for leaks.
  46.  

3.3L and 3.8L Engines

See Figures 9, 10, 11, 12, 13, 14, 15, 16, 17 and 18



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Fig. Fig. 9: Throttle cable attachment-3.3L and 3.8L engines



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Fig. Fig. 10: Electrical and vacuum connection to the throttle body



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Fig. Fig. 11: EGR tube connection



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Fig. Fig. 12: Electrical and vacuum connections to the intake manifold



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Fig. Fig. 13: MAP sensor electrical connection



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Fig. Fig. 14: Ignition coils



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Fig. Fig. 15: Intake manifold bolts



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Fig. Fig. 16: Fuel rail attaching bolts



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Fig. Fig. 17: Fuel injector wiring clip



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Fig. Fig. 18: Fuel rail removal

  1. Relieve the fuel pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the air cleaner and hose assembly.
  6.  
  7. Disconnect the throttle cable. Remove the wiring harness from the throttle cable bracket and intake manifold water tube.
  8.  
  9. Remove the vacuum hose harness from the throttle body.
  10.  
  11. Remove the PCV and brake booster hoses from the air intake plenum.
  12.  
  13. Remove the EGR tube flange from the intake plenum, if equipped.
  14.  
  15. Unplug the charge temperature sensor and unplug all vacuum hoses from the intake plenum.
  16.  
  17. Remove the cylinder head-to-intake plenum strut.
  18.  
  19. Disengage the MAP sensor and oxygen sensor connector. Remove the engine mounted ground strap.
  20.  
  21. Release the fuel hose quick-disconnect fittings and remove the hoses from the fuel rail. Plug the hoses.
  22.  
  23. Remove the Direct Ignition System (DIS) coils and the alternator bracket-to-intake manifold bolt.
  24.  
  25. Remove the intake manifold bolts and rotate the manifold back over the rear valve cover. Cover the intake manifold.
  26.  
  27. Remove the vacuum harness from the pressure regulator.
  28.  
  29. Remove the fuel tube retainer bracket screw and the fuel rail attaching bolts. Spread the retainer bracket to allow for clearance when removing the fuel tube.
  30.  
  31. Remove the fuel rail injector wiring clip from the alternator bracket.
  32.  
  33. Disconnect the camshaft sensor, coolant temperature sensor and engine temperature sensor.
  34.  
  35. Remove the fuel rail.
  36.  
  37. Position the fuel rail on a work bench, so that the injectors are easy to get at.
  38.  
  39. Remove the small connector retaining clip and unplug the injector. Remove the injector clip from the fuel rail and injector. Pull the injector straight off of the rail.
  40.  

To install:
  1. Lubricate the rubber O-ring with clean oil and install to the rail receiver cap. Install the injector clip to the slot in the injector, plug in the connector and install the connector clip.
  2.  
  3. Install the fuel rail.
  4.  
  5. Connect the camshaft sensor, coolant temperature sensor and engine temperature sensor.
  6.  
  7. Install the fuel rail injector wiring clip to the alternator bracket.
  8.  
  9. Install the fuel rail attaching bolts and fuel tube retainer bracket screw.
  10.  
  11. Install the vacuum harness to the pressure regulator.
  12.  
  13. Install the intake manifold with a new gasket. Install the bolts only finger-tight. Install the alternator bracket-to-intake manifold bolt and the cylinder head-to-intake manifold strut and bolts. Tighten the intake manifold mounting bolts to 21 ft. lbs. (28 Nm) starting from the middle and working outward. Tighten the bracket and strut bolts to 40 ft. lbs. (54 Nm).
  14.  
  15. Install or connect all items that were removed or disconnected from the intake manifold and throttle body.
  16.  
  17. Connect the fuel hoses to the rail. Push the fittings in until they click in place.
  18.  
  19. Install the air cleaner assembly.
  20.  
  21. Connect the negative battery cable and check for leaks using the DRB II or equivalent to activate the fuel pump.
  22.  

 
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