check engine CHRYSLER CARAVAN 2003 Service Manual

²Check for cylinder head mounting surface distor-
tion using a straightedge and thickness gauge. (Refer
to 9 - ENGINE/CYLINDER HEAD - INSPECTION)
INSTALLATION - LOWER INTAKE MANIFOLD
(1) Place a bead (approximately 1/4 in. diameter)
of MopartEngine RTV GEN II onto each of thefour
manifold to cylinder head gasket corners (Fig. 122).
(2) Carefully install the new intake manifold gas-
ket (Fig. 121). Tighten end seal retainer screws to 12
N´m (105 in. lbs.).
(3) Install lower intake manifold (Fig. 121). Install
the bolts and torque to 1 N´m (10 in. lbs.). Then
torque bolts to 22 N´m (200 in. lbs.) in sequence
shown in (Fig. 123). Then torque again to 22 N´m
(200 in. lbs.). After intake manifold is in place,
inspect to make sure seals are in place.
(4) Install the fuel injectors and rail assembly.
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
FUEL RAIL - INSTALLATION)
(5) Connect fuel injector electrical harness.
(6) Connect the engine coolant temperature sensor
(Fig. 120).
(7) Connect the heater supply (Fig. 120) and radi-
ator upper hoses to manifold.
(8) Connect the fuel line. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)(9) Install the upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION)
(10) Connect negative battery cable.
Fig. 120 ECT SENSOR & HEATER SUPPLY
1 - ENGINE COOLANT TEMPERATURE SENSOR
2 - CONNECTOR - ENGINE COOLANT SENSOR
3 - FITTING - HEATER SUPPLY
Fig. 121 INTAKE MANIFOLD - LOWER
1 - INTAKE MANIFOLD - LOWER
2 - BOLT - GASKET END SEAL RETAINER
3 - GASKET
4 - BOLT - LOWER INTAKE MANIFOLD
Fig. 122 Intake Manifold Gasket Sealing
1 - SEALER LOCATIONS
RSENGINE 3.3/3.8L9 - 149
INTAKE MANIFOLD - LOWER (Continued)
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(12) Lower vehicle and remove the power steering
pump support strut upper bolt (Fig. 125).
(13) Remove bolts attaching exhaust manifold to
cylinder head and remove manifold (Fig. 127).
(14) Inspect and clean manifold. (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
CLEANING) (Refer to 9 - ENGINE/MANIFOLDS/
EXHAUST MANIFOLD - INSPECTION)
CLEANING
(1) Discard gasket (if equipped) and clean all sur-
faces of manifold and cylinder head.
INSPECTION
Inspect exhaust manifolds for damage or cracks
and check distortion of the cylinder head mounting
surface and exhaust crossover mounting surface with
a straightedge and thickness gauge (Fig. 128).
Manifold surface flatness limits should not exceed
1.0 mm (0.039 in.).
INSTALLATION
(1) Position exhaust manifold on cylinder head and
install bolts to center runner (cylinder #3) and initial
tighten to 2.8 N´m (25 in. lbs.) (Fig. 127)
(2) Using a new gasket, attach crossover pipe to
exhaust manifold and tighten bolts to 41 N´m (30 ft.
lbs.) (Fig. 124).NOTE: Inspect crossover pipe fasteners for damage
from heat and corrosion. The cross-over bolts are
made of a special stainless steel alloy. If replace-
ment is required, OEM bolts are highly recom-
mended.
(3) Install the remaining manifold attaching bolts.
Tighten all bolts to 23 N´m (200 in. lbs.).
(4) Position the power steering pump support strut
and install upper bolt (Fig. 125).
(5) Install heat shield and attaching screws (Fig.
127).
(6) Install and connect upstream oxygen sensor
(Fig. 127).
(7) Raise the vehicle.
(8) Attach catalytic converter pipe to exhaust man-
ifold using new gasket and tighten bolts to 37 N´m
(27 ft. lbs.) (Fig. 126).
(9) Connect downstream oxygen sensor connector.
(10) Tighten the power steering pump support
strut lower bolt (Fig. 125).
(11) Install the belt splash shield and lower the
vehicle.
(12) Install the wiper module. (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION)
(13) Connect battery negative cable.
Fig. 127 EXHAUST MANIFOLD - RIGHT
1 - SCREW - HEAT SHIELD
2 - HEAT SHIELD - UPPER
3 - BOLT - EXHAUST MANIFOLD
4 - HEAT SHIELD - LOWER
5 - EXHAUST MANIFOLD - RIGHT
6 - OXYGEN SENSOR - UPSTREAM
Fig. 128 Check Exhaust Manifold Mounting
1 - STRAIGHT EDGE
2 - CROSSOVER PIPE MOUNTING SURFACE
3 - FEELER GAUGE
RSENGINE 3.3/3.8L9 - 151
EXHAUST MANIFOLD - RIGHT (Continued)
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EXHAUST MANIFOLD - LEFT
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove bolts attaching crossover pipe to
exhaust manifold (Fig. 129).
(3) Disconnect left cylinder bank spark plug wires.
(4) Remove heat shield attaching bolts (Fig. 130).
(5) Remove bolts attaching exhaust manifold to
cylinder head (Fig. 130).
(6) Remove the exhaust manifold (Fig. 130).(7) Inspect and clean manifold. (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
INSPECTION) (Refer to 9 - ENGINE/MANIFOLDS/
EXHAUST MANIFOLD - CLEANING)
CLEANING
(1) Discard gasket (if equipped) and clean all sur-
faces of manifold and cylinder head.
INSPECTION
Inspect exhaust manifolds for damage or cracks
and check distortion of the cylinder head mounting
surface and exhaust crossover mounting surface with
a straightedge and thickness gauge (Fig. 131).
Manifold surface flatness limits should not exceed
1.0 mm (0.039 in.).
INSTALLATION
(1) Position exhaust manifold on cylinder head
(Fig. 130). Install bolts to center runner (cylinder #4)
and initial tighten to 2.8 N´m (25 in. lbs.).
(2) Using a new gasket, attach crossover pipe to
exhaust manifold and tighten bolts to 41 N´m (30 ft.
lbs.) (Fig. 129).
NOTE: Inspect crossover pipe fasteners for damage
from heat and corrosion. The cross-over bolts are
made of a special stainless steel alloy. If replace-
ment is required, OEM bolts are highly recom-
mended.
(3) Position heat shield on manifold (Fig. 130).
(4) Install the remaining manifold attaching bolts.
Tighten all bolts to 23 N´m (200 in. lbs.).
(5) Install and tighten heat shield attaching nut to
12 N´m (105 in. lbs.) (Fig. 130).
(6) Connect battery negative cable.
Fig. 129 CROSS-OVER PIPE
1 - CROSS-OVER PIPE
2 - BOLT
3 - GASKET
4 - FLAG NUT
Fig. 130 EXHAUST MANIFOLD - LEFT
1 - EXHAUST MANIFOLD - LEFT BANK
2 - HEAT SHIELD
3 - NUT - HEAT SHIELD
4 - BOLT - EXHAUST MANIFOLD
Fig. 131 Check Exhaust Manifold Mounting
1 - STRAIGHT EDGE
2 - CROSSOVER PIPE MOUNTING SURFACE
3 - FEELER GAUGE
9 - 152 ENGINE 3.3/3.8LRS
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(2) Install sprocket using Special Tool 8452 (Fig.
142). Install sprocket until it is fully seats on the
crankshaft.(3) Install the timing chain and camshaft sprocket.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLATION)
INSTALLATION - TIMING CHAIN AND
CAMSHAFT SPROCKET
(1) Rotate crankshaft so the timing arrow is to the
12 o'clock position (Fig. 140).
NOTE: Lubricate timing chain and sprockets with
clean engine oil before installation.
(2) While holding camshaft sprocket and chain in
hand, place timing chain around the sprocket, align-
ing the plated link with the dot on the sprocket. Posi-
tion the timing arrow to the 6 o'clock position (Fig.
140).
(3) Place timing chain around crankshaft sprocket
with the plated link lined up with the dot on the
sprocket. Install camshaft sprocket into position.
(4) Use a straight edge to check alignment of tim-
ing marks.
(5) Install camshaft sprocket bolt and washer.
Tighten bolt to 54 N´m (40 ft. lbs.).
(6) Rotate crankshaft 2 revolutions and check tim-
ing mark alignment (Fig. 140). If timing marks do
not line up, remove camshaft sprocket and realign.
(7) Install the timing chain cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
(8) Connect negative cable to battery.
Fig. 140 Timing Mark Alignment
1 - CAMSHAFT SPROCKET TIMING MARK (DOT)
2 - PLATED LINK
3 - CRANKSHAFT SPROCKET TIMING MARK (DOT)
4 - ARROWS
Fig. 141 CRANKSHAFT SPROCKET - REMOVAL
1 - SPECIAL TOOL 5048-6
2 - SPECIAL TOOL 5048-1
3 - SPECIAL TOOL 8450
4 - CRANKSHAFT SPROCKET
5 - SPECIAL TOOL 8539
Fig. 142 CRANKSHAFT SPROCKET - INSTALLATION
1 - SPECIAL TOOL 8452-3
2 - SPECIAL TOOL 8452-1
3 - CRANKSHAFT SPROCKET
4 - THRUST BEARING / WASHER
RSENGINE 3.3/3.8L9 - 157
TIMING CHAIN AND SPROCKETS (Continued)
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EXHAUST SYSTEM
TABLE OF CONTENTS
page page
EXHAUST SYSTEM
DESCRIPTION..........................1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EXCESSIVE
EXHAUST SYSTEM NOISE...............2
DIAGNOSIS AND TESTING - EXHAUST
SYSTEM RESTRICTION CHECK...........2
INSPECTION...........................3
ADJUSTMENTS.........................3
SPECIFICATIONS
TORQUE.............................3
SPECIAL TOOLS
EXHAUST SYSTEM.....................4
CATALYTIC CONVERTER
DESCRIPTION..........................4
OPERATION............................4
REMOVAL.............................5INSPECTION...........................5
INSTALLATION..........................6
CROSS-OVER PIPE - 3.3/3.8L
REMOVAL.............................6
INSTALLATION..........................6
HEAT SHIELDS
DESCRIPTION..........................6
OPERATION............................7
REMOVAL.............................7
INSTALLATION..........................7
MUFFLER
REMOVAL.............................7
INSTALLATION..........................7
RESONATOR
REMOVAL.............................9
INSTALLATION..........................9
EXHAUST SYSTEM
DESCRIPTION
The exhaust system consists of a catalytic con-
verter, muffler, and a resonator with connecting pipes
in-between (Fig. 1). The system is serviced in two
sections; the catalytic converter and pipe, and the
muffler and resonator with connecting pipe. A band
clamp is used to connect the joint between the twocomponents. Three support hanger rods with rubber
isolators are used to support and isolate the exhaust
system. A flexible joint, integral to the catalytic con-
verter, allows for engine movement. On vehicles
equipped with AWD, an additional heat shield is
mounted to the catalytic converter. The exhaust sys-
tem is tuned for each vehicle/powertrain combination.
Fig. 1 Exhaust System - Typical (All Vehicles)
1 - CATALYTIC CONVERTER 4 - SUPPORT - RESONATOR
2 - BAND CLAMP 5 - RESONATOR
3 - SUPPORTS - MUFFLER 6 - MUFFLER
RSEXHAUST SYSTEM11-1
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DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EXCESSIVE
EXHAUST SYSTEM NOISE
CONDITION POSSIBLE CAUSES CORRECTION
EXCESSIVE EXHAUST NOISE
(UNDER HOOD)1. Exhaust manifold cracked or
broken.1. Replace manifold.
2. Manifold to cylinder head leak. 2. Tighten manifold and/or replace
gasket.
3. EGR Valve to manifold gasket
leakage.3. Tighten fasteners or replace
gasket.
4. EGR Valve to EGR tube gasket
leakage.4. Tighten fasteners or replace
gasket.
5. EGR tube to manifold tube
leakage.5. Tighten tube nut.
6. Exhaust flex-joint to manifold
leak.6. Tighten joint fasteners and/or
replace gasket.
7. Exhaust flex-joint. 7. Replace catalytic converter
assembly.
8. Pipe and shell noise from front
exhaust pipe.8. Characteristic of single wall pipe.
EXCESSIVE EXHAUST NOISE 1. Leak at exhaust pipe joints. 1. Tighten clamps at leaking joints.
2. Burned or rusted out muffler
assembly or exhaust pipe.2. Replace muffler resonator tailpipe
assembly or exhaust pipe with
catalytic converter assembly.
3. Burned or rusted out resonator. 3. Replace muffler resonator tailpipe
assembly.
4. Restriction in exhaust system. 4. Perform Exhaust System
Restriction Check. Replace
component as necessary.
5. Converter material in muffler. 5. Replace muffler and converter
assemblies. Check fuel injection and
ignition systems for proper
operation.
DIAGNOSIS AND TESTING - EXHAUST SYSTEM
RESTRICTION CHECK
Exhaust system restriction can be checked by mea-
suring back pressure using the DRB IIItand PEP
module pressure tester.
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER WORK AROUND OR ATTEMPT
TO SERVICE ANY PART OF THE EXHAUST SYSTEM
UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE
TAKEN WHEN WORKING NEAR THE CATALYTIC
CONVERTER. THE TEMPERATURE OF THE CON-VERTER RISES TO A HIGH LEVEL AFTER A SHORT
PERIOD OF ENGINE OPERATION TIME.
NOTE: For Special Tool identification, (Refer to 11 -
EXHAUST SYSTEM - SPECIAL TOOLS).
(1) Disconnect and remove the upstream (before
catalytic converter) oxygen sensor. (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/O2 SENSOR -
REMOVAL)
(2) Install the Exhaust Back Pressure Fitting
Adaptor CH8519.
(3) Connect the Low Pressure Sensor (15 psi)
CH7063 to the back pressure fitting.
11 - 2 EXHAUST SYSTEMRS
EXHAUST SYSTEM (Continued)
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The combustion reaction caused by the catalyst
releases additional heat in the exhaust system, caus-
ing temperature increases in the area of the reactor
under severe operating conditions. Such conditions
can exist when the engine misfires or otherwise does
not operate at peak efficiency.Do notremove spark
plug wires from plugs or by any other means short
out cylinders, if exhaust system is equipped with a
catalytic converter. Failure of the catalytic converter
can occur due to temperature increases caused by
unburned fuel passing through the converter. This
deterioration of the catalyst core can result in exces-
sively high emission levels, noise complaints, and
exhaust restrictions.
Unleaded gasoline must be used to avoid ruining
the catalyst core. Do not allow engine to operate
above 1200 RPM in neutral for extended periods over
5 minutes. This condition may result in excessive
exhaust system/floor pan temperatures because of no
air movement under the vehicle.
The flex joint allows flexing as the engine moves,
preventing breakage that could occur from the back-
and-forth motion of a transverse mounted engine.
CAUTION: Due to exterior physical similarities of
some catalytic converters with pipe assemblies,
extreme care should be taken with replacement
parts. There are internal converter differences
required in some parts of the country (particularly
vehicles built for States with strict emission
requirements) and between model years.
REMOVAL
(1) Loosen clamp and disconnect the muffler/reso-
nator assembly from catalytic converter pipe.
(2) Disconnect downstream oxygen sensor electri-
cal connector (Fig. 4). For removal of downstream
oxygen sensor, (Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/O2 SENSOR - REMOVAL).
(3) Remove catalytic converter to exhaust manifold
attaching fasteners (Fig. 5).
(4) Remove catalytic converter and gasket (Fig. 5).
INSPECTION
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER ATTEMPT TO SERVICE ANY
PART OF THE EXHAUST SYSTEM UNTIL IT IS
COOLED. SPECIAL CARE SHOULD BE TAKEN
WHEN WORKING NEAR THE CATALYTIC CON-
VERTER. THE TEMPERATURE OF THE CONVERTER
RISES TO A HIGH LEVEL AFTER A SHORT PERIOD
OF ENGINE OPERATION TIME.Check catalytic converter for a flow restriction.
(Refer to 11 - EXHAUST SYSTEM - DIAGNOSIS
AND TESTING) Exhaust System Restriction Check
for procedure.
Fig. 4 Downstream Oxygen Sensor
1 - OXYGEN SENSOR CONNECTOR
2 - CATALYTIC CONVERTER
3 - DOWNSTREAM OXYGEN SENSOR
4 - ENGINE HARNESS CONNECTOR
Fig. 5 Catalytic Converter to Exhaust Manifold
1 - FLAG NUT
2 - GASKET
3 - BOLT
4 - CATALYTIC CONVERTER
RSEXHAUST SYSTEM11-5
CATALYTIC CONVERTER (Continued)
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When installing hoses, ensure that they are routed
away from contact with other vehicle components
that could rub against them and cause failure. Avoid
contact with clamps or other components that cause
abrasions or scuffing. Ensure that rubber hoses are
properly routed and avoid heat sources.
The hose clamps have rolled edges to prevent the
clamp from cutting into the hose. Only use clamps
that are original equipment or equivalent. Other
types of clamps may cut into the hoses and cause
high pressure fuel leaks. Tighten hose clamps to 1
N´m (9 in. lbs.) torque.
Inspect all hose connections such as clamps, cou-
plings and fittings to make sure they are secure and
leaks are not present. The component should be
replaced immediately if there is any evidence of deg-
radation that could result in failure.
Never attempt to repair a plastic fuel line/tube.
Replace as necessary.
Avoid contact of any fuel tubes/hoses with other
vehicle components that could cause abrasions or
scuffing. Be sure that the plastic fuel lines/tubes are
properly routed to prevent pinching and to avoid heat
sources.
FUEL PRESSURE REGULATOR
OPERATION
The fuel system uses a nonadjustable pressure reg-
ulator that maintains fuel system pressure at
approximately 400  34 kPa (58  5 psi). The fuel
pressure regulator contains a diaphragm, calibrated
spring and a fuel return valve. The spring pushes
down on the diaphragm and closes off the fuel return
port. System fuel pressure reflects the amount of fuel
pressure required to open the return port.
The pressure regulator is a mechanical device that
is NOT controlled by the PCM or engine vacuum.
REMOVAL
The fuel pressure regulator is part of the fuel
pump module (Fig. 9). Remove the fuel pump module
from the fuel tank to access the fuel pressure regula-
tor. Refer to the Fuel Pump Module removal in this
section.
(1) Spread tangs on pressure regulator retainer.
(2) Pry fuel pressure regulator out of housing.
(3) Ensure both upper and lower O-rings were
removed with regulator.
INSTALLATION
The fuel pressure regulator is part of the fuel
pump module. Remove the fuel pump module from
the fuel tank to access the fuel pressure regulator.Refer to the Fuel Pump Module removal in this sec-
tion.
(1) Lightly lubricate the O-rings with clean engine
oil and place them into opening in pump module (Fig.
9).
(2) Push regulator into opening in pump module.
(3) Fold tangs on regulator retainer over tabs on
housing.
FUEL PUMP
DESCRIPTION
The electric fuel pump is located in and is part of
the fuel pump module. It is a positive displacement,
gerotor type, immersible pump with a permanent
magnet electric motor. The fuel pump module is sus-
pended in fuel in the fuel tank.
OPERATION
The pump draws fuel through a strainer and
pushes it through the motor to the outlet. The pump
contains a check valve. The valve, in the pump out-
let, maintains pump pressure during engine off con-
ditions, for a short while. It is normal for fuel
pressure to drop to zero after cooldown. The fuel
pump relay provides voltage to the fuel pump. The
fuel pump has a maximum deadheaded pressure out-
put of approximately 880 kPa (130 psi). The regula-
tor adjusts fuel system pressure to approximately
400 kpa  34 kpa (58 psi   5 psi).
NOTE: Checkvalve maintains volume of fuel in the
rail and lines, not pressure.
Fig. 9 Fuel Pressure Regulator O-rings
1 - UPPER O-RING
2 - LOWER 0-RING
RSFUEL DELIVERY14-7
FUEL LINES (Continued)
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FUEL PUMP MODULE
DESCRIPTION
The fuel pump module is installed in the top of the
fuel tank (Fig. 10) .
The fuel pump module contains the following:
²Electric fuel pump
²Fuel pump reservoir
²Inlet strainer
²Fuel pressure regulator
²Fuel gauge sending unit
²Fuel supply line connection
The inlet strainer, fuel pressure regulator
and fuel level sensor are the only serviceable
items. If the fuel pump or electrical wiring har-
ness requires service, replace the fuel pump
module.
The electric fuel pump is located in and is part of
the fuel pump module. It is a positive displacement,
gerotor type, immersible pump with a permanent
magnet electric motor.
OPERATION
The pump draws fuel through a strainer and
pushes it through the motor to the outlet. The pump
contains one check valve. The check valve, in the
pump outlet, maintains pump pressure during engine
off conditions. The fuel pump relay provides voltage
to the fuel pump.
The fuel pump has a maximum deadheaded pres-
sure output of approximately 880 kPa (130 psi). The
regulator adjusts fuel system pressure to approxi-
mately 400  34 kPa (58  5 psi).
FUEL PUMP ELECTRICAL CONTROL
Voltage to operate the electric pump is supplied
through the fuel pump relay. For an electrical opera-
tional description of the fuel pump refer to fuel Pump
RelayÐPCM Output.
ELECTRICAL PUMP REPLACEMENT
The electric fuel pump is not serviceable. If the
fuel pump or electrical wiring harness needs replace-
ment, the complete fuel pump module must be
replaced. Perform the Fuel System Pressure Release
procedure before servicing the fuel pump.
REMOVAL
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE.
(1) Remove fuel filler cap and perform Fuel Sys-
tem Pressure Release procedure.
(2) Disconnect negative cable from auxiliary
jumper terminal.
(3) Drain fuel tank, refer to the Fuel Tank proce-
dure in the Fuel Delivery section.
(4) Remove fuel tank, refer to the Fuel Tank
removal section.
(5) Clean top of tank to remove loose dirt and
debris.
(6) Using a brass punch and hammer remove lock-
nut to release pump module (Fig. 11).
Fig. 10 Fuel Pump Module
1 - INLET STRAINER
2 - FUEL RESERVOIR
3 - FUEL PRESSURE REGULATOR
4 - FUEL LEVEL SENSOR
Fig. 11 FUEL PUMP MODULE LOCKING RING
14 - 8 FUEL DELIVERYRS
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WARNING: THE FUEL RESERVOIR OF THE FUEL
PUMP MODULE DOES NOT EMPTY OUT WHEN THE
TANK IS DRAINED. THE FUEL IN THE RESERVOIR
MAY SPILL OUT WHEN THE MODULE IS REMOVED.
(7) Remove fuel pump module and O-ring from
tank (Fig. 12). Discard O-ring.
INSTALLATION
NOTE: Be careful not to allow dirt/debris to fall into
the fuel tank.
(1) Wipe seal area of tank clean and place a new
O-ring seal in position on pump.
(2) Position fuel pump module in tank.
(3) Tighten lockring using a brass punch and ham-
mer to install the lockring (Fig. 11).
(4) Install fuel tank, refer to the Fuel Tank instal-
lation section.
(5) Lower vehicle.
(6) Connect negative cable battery.
(7) Fill fuel tank. Use the DRB IIItscan tool to
pressurize the fuel system. Check for leaks.
(8) Install fuel filler cap.
FUEL RAIL
REMOVAL
REMOVAL - 2.4L
(1) Perform fuel system pressure release procedure
before servicing or starting repairs.Refer to
Fuel System Pressure Release Procedure in this sec-
tion.(2) Disconnect negative cable from battery.
(3) Disconnect the wiring connectors for fuel injec-
tors harness (Fig. 13).
(4) Remove wiring harness from brackets.
(5) Disconnect the connectors from the fuel injec-
tors.
(6) Remove harness from vehicle.
(7) Remove fuel hose quick connect fitting from the
chassis tube.Refer to Fuel Hoses, Clamps and
Quick Connect Fittings in this Section.Place a
shop towel under the connections to absorb any fuel
spilled from the fitting.
WARNING: WRAP A SHOP TOWEL AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
(8) Remove fuel rail attaching bolts.
(9) Remove fuel rail. Be careful not to damage the
injector O-rings upon removal from their ports.
REMOVAL - 3.3/3.8L
(1) Perform fuel system pressure release procedure
before servicing or starting repairs.Refer to
Fuel System Pressure Release Procedure in this sec-
tion.
(2) Disconnect negative cable from battery.
(3) Remove upper intake manifold, refer to the
Engine/Manifolds/Upper Intake for more informa-
tion..
(4) Cover intake manifold with suitable cover
when servicing.
(5) Remove the fuel hose quick connect fitting from
the chassis tube.Refer to Fuel Hoses, Clamps
and Quick Connect Fittings in this Section.
WARNING: WRAP A SHOP TOWEL AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
(6) Remove the fuel rail attaching bolts (Fig. 14).
Fig. 12 Fuel Pump Module Removal
1 - FUEL PUMP MODULE
2 - O-RING
Fig. 13 FUEL RAIL AND INJECTORS 2.4L
1 - Fuel Injectors
2 - Fuel Rail
RSFUEL DELIVERY14-9
FUEL PUMP MODULE (Continued)
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