OEM 2000 Dodge Caravan Fuel Rail

2000 Dodge Caravan Fuel Rail Parts and Q&A

• Q: How to Service a Fuel Rail on 2000 Dodge Caravan?

  A: First, let the pressure out of the fuel system and remove the negative battery cable for the process. Disconnect the air cleaner inlet hose from the throttle body, then remove both the throttle and the speed control cables from the throttle lever by pressing out the retaining tabs. First, disconnect the connectors of the throttle position sensor and the idle air control motor and then follow with the vacuum lines from the intake plenum fittings. Unplug the wiring for the intake air temperature and MAP sensors. Working on a shop towel below, separate the fuel hose quick connect from the hose barb at the chassis. First, unbolt the bottom of the intake support bracket, then get rid of the intake manifold screws and the bolts that secure the fuel rail. When removing the fuel rail, be very careful so you don't harm the injector O-rings. Before mounting, spray the holes with cleaning fluid, then remove and clean any unclean or torn O-rings and lubricate them with engine oil for simple installation. Pull back the syringe plungers and insert each injector so that its tip fits into its port. Then push the assembly toward the shell until it is seated. Put the fuel rail mounting bolts in, tighten them to 22 Nm (200 in. lbs.) and put a new gasket on the intake manifold before placing it. Start tightening from the middle of the wheel and head outward, getting all the retaining bolts up to 23 Nm (200 in. lbs.), repeating until the bolts are all tight. Connect the fuel hose quick connector fitting to the chassis tubes and see that it clicks in, then fasten the intake support bracket bolts. Repair the MAP sensor and the intake air temperature sensor wiring, then fasten the vacuum lines back to the intake manifold fitting, next connect the idle air control motor and turn to the throttle position sensor connector. After that, link the throttle and speed control cables from the bracket to the throttle lever, tie the air cleaner pipe to the throttle body, tighten the clamps, reattach the negative battery cable and use the DRB scanner to put pressure on the fuel lines as you look for any leaks.