GrandCaravan 2008

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



3.3L & 3.8L Engines

Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009


CAUTION
The fuel system is under a constant pressure (even with the engine OFF). Before servicing any part on the fuel system, the fuel system pressure must be released.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Release the fuel system pressure. Refer to Relieving Fuel System Pressure.
  4.  
  5. Disconnect and isolate the negative battery cable at the battery.
  6.  
  7. Remove the clean air hose from the throttle body.
  8.  
  9. Use a fuel line release tool to disconnect the quick-connect fuel line from the fuel rail.
  10.  
  11. Remove the upper intake manifold. Refer to Intake manifold, removal & installation.
    NOTE
    Mark the fuel injector electrical harness connectors with the correct corresponding cylinder numbers.

  12.  
  13. Disconnect the fuel injector electrical connectors.
  14.  
  15. Remove the fuel rail mounting bolts from the fuel rail.
  16.  
  17. Lift the fuel rail straight up off of the lower intake manifold.
    NOTE
    When replacing individual fuel injectors, each fuel injector must be installed to its original position. Mark or tag each fuel injector to identify the correct cylinder.



    Click image to see an enlarged view

    Fig. Lift the fuel rail straight up off of the lower intake manifold-3.3L and 3.8L engines

  18.  
  19. Remove the retaining clips from the fuel injectors at the fuel rail.
  20.  
  21. Remove the fuel injector from the fuel rail.

    Click image to see an enlarged view

    Fig. Remove the retaining clips from the fuel injectors at the fuel rail-3.3L and 3.8L engines

  22.  

To install:


NOTE
Inspect each O-ring seal on all the fuel injectors, replace O-ring seal if any damage is noted.

  1. Lubricate each fuel injector O-ring with a light drop of clean engine oil.
    NOTE
    If individual fuel injectors are being replaced, return the remaining fuel injectors to the original positions noted during removal.

  2.  
  3. Install the fuel injectors into the fuel rail, attach the retaining clips on the fuel injectors, and make sure that each fuel injector is seated properly into the fuel rail.
  4.  
  5. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each of the injectors.
  6.  
  7. Insert the fuel injector nozzles into the openings in the lower intake manifold. Seat the injectors in place.
  8.  
  9. Install the fuel rail bolts and tighten the bolts to 106 inch lbs. (12 Nm).
  10.  
  11. Correctly position and connect the fuel injector electrical harness connectors to the fuel injectors.
  12.  
  13. Install the intake manifold. Refer to Intake manifold, removal & installation.
    WARNING
    Make sure the fuel line quick connector is connected properly. Failure to connect the fuel line correctly may result in a fuel leak at the rail assembly. Fuel leaked onto a hot engine may ignite resulting in damage to the vehicle.

  14.  
  15. Connect the quick connect fuel line to the fuel rail.
  16.  
  17. Install the clean air hose to the throttle body.
  18.  
  19. Connect the negative battery cable, tighten the nut to 45 inch lbs. (5 Nm).
  20.  
  21. Use the scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.
  22.  

4.0L Engine

Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009


CAUTION
The fuel system is under a constant pressure (even with the engine OFF). Before servicing any part on the fuel system, the fuel system pressure must be released.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Release the fuel system pressure. Refer to Relieving Fuel System Pressure.
  4.  
  5. Disconnect and isolate the negative battery cable at the battery.
  6.  
  7. Remove the clean air hose from the throttle body.
  8.  
  9. Use a fuel line release tool to disconnect the quick-connect fuel line (1) from the fuel rail (2).

    Click image to see an enlarged view

    Fig. Use a fuel line release tool to disconnect the quick-connect fuel line (1) from the fuel rail (2)-4.0L engine

  10.  
  11. Remove the upper intake manifold. Refer to Intake Manifold, removal & installation.
    NOTE
    Mark the fuel injector electrical harness connectors with the correct corresponding cylinder numbers.

  12.  
  13. Disconnect the fuel injector electrical connectors.
  14.  
  15. Remove the fuel rail mounting bolts from the fuel rail.

    Click image to see an enlarged view

    Fig. Remove the fuel rail mounting bolts from the fuel rail-4.0L engine

  16.  
  17. Lift the fuel rail straight up off of the cylinder heads.
  18.  
  19. Remove the retaining clips from the fuel injectors at the fuel rail.
    NOTE
    When replacing individual fuel injectors, each fuel injector must be installed to its original position. Mark or tag each fuel injector to identify the correct cylinder.

  20.  
  21. Remove the fuel injectors (1) from the fuel rail (2).

    Click image to see an enlarged view

    Fig. Remove the fuel injectors (1) from the fuel rail (2)-4.0L engine

  22.  

To install:


NOTE
Inspect each O-ring seal on all the fuel injectors, replace O-ring seal if any damage is noted.

  1. Lubricate each fuel injector O-ring with a light drop of clean engine oil.
    NOTE
    If individual fuel injectors are being replaced, return the remaining fuel injectors to the original positions noted during removal.

  2.  
  3. Install the fuel injectors into the fuel rail, attach the retaining clips on the fuel injectors, and make sure that each fuel injector is seated properly into the fuel rail.
  4.  
  5. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each of the fuel injectors.
  6.  
  7. Insert the fuel injector nozzles into the openings in the cylinder heads. Seat the injectors in place. Install the fuel rail bolts and tighten the bolts to 21 ft. lbs. (28 Nm).
  8.  
  9. Correctly position and connect the fuel injector electrical harness connectors to the fuel injectors.
    WARNING
    Make sure the fuel line quick connector is connected properly. Failure to connect the fuel line correctly may result in a fuel leak at the rail assembly. Fuel leaked onto a hot engine may ignite resulting in damage to the vehicle.

  10.  
  11. Connect the quick connect fuel line (1) to the fuel rail (2).
  12.  
  13. Install the upper intake manifold. Refer to Intake Manifold, removal & installation.
  14.  
  15. Connect the negative battery cable, tighten the nut to 45 inch lbs. (5 Nm).
  16.  
  17. Use the scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.
  18.  

 
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