2003 CHRYSLER CARAVAN engine

(2) Wrap wires into groove in back of level sensor
(Fig. 7) .
(3) While feeding wires into guide grooves, slide
level sensor up into channel until it snaps into place
(Fig. 8) . Ensure tab at bottom of sensor locks in
place.
(4) Install level sensor wires in connector. Push
the wires up through the connector and then pull
them down until they lock in place. Ensure signal
and ground wires are installed in the correct posi-
tion.
(5) Install locking wedge on connector.
(6) Push connector up into bottom of fuel pump
module electrical connector.
(7) Install fuel pump module. Refer to Fuel Pump
Module in this section.FUEL LINES
DESCRIPTION - FUEL LINES/HOSES AND
CLAMPS
Also refer to Quick-Connect Fittings.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRES-
SURE MUST BE RELEASED. REFER TO THE FUEL
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP.
The lines/tubes/hoses used on fuel injected vehicles
are of a special construction. This is due to the
higher fuel pressures and the possibility of contami-
nated fuel in this system. If it is necessary to replace
these lines/tubes/hoses, only those marked EFM/EFI
may be used.
If equipped:The hose clamps used to secure rub-
ber hoses on fuel injected vehicles are of a special
rolled edge construction. This construction is used to
prevent the edge of the clamp from cutting into the
hose. Only these rolled edge type clamps may be
used in this system. All other types of clamps may
cut into the hoses and cause high-pressure fuel leaks.
Use new original equipment type hose clamps.
STANDARD PROCEDURE - HOSES AND CLAMP
Inspect all hose connections (clamps and quick con-
nect fittings) for completeness and leaks. Replace
cracked, scuffed, or swelled hoses. Replace hoses that
rub against other vehicle components or show sign of
wear.
Fuel injected vehicles use specially constructed
hoses. When replacing hoses, only use hoses marked
EFM/EFI.
Fig. 6 Level Sensor Removal/Installation
1 - OPENING IN MODULE
2 - FUEL LEVEL SENSOR
Fig. 7 Groove in Back Side of Level Sensor
1 - WRAP WIRES IN GROOVE
2 - REAR VIEW OF LEVEL SENSOR
Fig. 8 Installation Channel
1 - CHANNEL FOR LEVEL SENSOR
2 - PUMP MODULE
14 - 6 FUEL DELIVERYRS
FUEL LEVEL SENDING UNIT / SENSOR (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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(7) Remove fuel rail. Be careful not to damage the
injector O-rings upon removal from their ports.
INSTALLATION
INSTALLATION - 2.4L
(1) Ensure injector holes are clean. Replace
O-rings if damaged.
(2) Lubricate injector O-rings with a drop of clean
engine oil to ease installation.
(3) Put the tip of each injector into their ports.
Push the assembly into place until the injectors are
seated in the ports.
(4) Install the fuel rail mounting bolts. Tighten
bolts to 22 N´m (200 in. lbs.) torque.
(5) Connect the connectors to the fuel injectors.
(6) Install wiring harness to brackets.
(7) Connect the wiring connectors to fuel injectors
harness (Fig. 13).
(8) Connect negative battery cable.
(9) Use the DRBIIItscan tool to pressurize the
fuel system. Check for leaks.
INSTALLATION - 3.3/3.8L
(1) Ensure injector holes are clean. Replace
O-rings if damaged.
(2) Lubricate injector O-rings with a drop of clean
engine oil to ease installation.
(3) Put the tip of each injector into their ports.
Push the assembly into place until the injectors are
seated in the ports.
(4) Install the fuel rail mounting bolts. Tighten
bolts to 22 N´m (200 in. lbs.) torque.
(5) Remove covering on lower intake manifold and
clean surface.(6) Install the Upper Intake Manifold, refer to
Engine/Manifolds/Upper Intake for more information.
(7) Install fuel hose quick connector fitting to chas-
sis tubes.Refer to Fuel Hoses, Clamps and
Quick Connect Fittings in this Section.Push the
fitting onto the chassis tube until it clicks into place.
Pull on the fitting to ensure complete insertion.
(8) Connect negative cable to battery.
(9) Use the DRBIIItscan tool to pressurize the
fuel system. Check for leaks.
FUEL TANK
DESCRIPTION
The fuel tank is constructed of a plastic material.
Its main functions are for fuel storage and for place-
ment of the fuel pump module. The tank is made
from High density Polyethylene (HDPE) material.If
equipped with ORVR (Onboard Refueling Vapor
Recovery) it has been added to the fuel tank to con-
trol refueling vapor emissions.
OPERATION
All models pass a full 360 degree rollover test
without fuel leakage. To accomplish this, fuel and
vapor flow controls are required for all fuel tank con-
nections.
All models are equipped with either one or two
rollover valves mounted into the top of the fuel tank
(or pump module).
An evaporation control system is connected to the
rollover valve(s)/control valve(Refer to 25 - EMIS-
SIONS CONTROL/EVAPORATIVE EMISSIONS/
ORVR - OPERATION) to reduce emissions of fuel
vapors into the atmosphere, when the tank is vented
due to vapor expansion in the tank. When fuel evap-
orates from the fuel tank, vapors pass through vent
hoses or tubes to a charcoal canister where they are
temporarily held. When the engine is running, the
vapors are drawn into the intake manifold. In addi-
tion, fuel vapors produced during vehicle refueling
are allowed to pass through the vent hoses/tubes to
the charcoal canister(s) for temporary storage (prior
to being drawn into the intake manifold). All models
are equipped with a self-diagnosing system using a
Leak Detection Pump (LDP) or Natural Vacuum
Leak Detection (NVLD). Refer to the Emission Con-
trol System for additional information.
INLET CHECK VALVE
All vehicles have an inlet check valve on the inside
of the fuel tank at the filler inlet
The valve prevents fuel from splashing back on
customer during vehicle refueling. The valve is a
non-serviceable item.
Fig. 14 FUEL INJECTORS 3.3/3.8L
14 - 10 FUEL DELIVERYRS
FUEL RAIL (Continued)
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REMOVAL
(1) Remove fuel filler cap and perform Fuel Sys-
tem Pressure Release procedure (Fig. 15).
(2) Disconnect negative cable from battery.
(3) Insert fuel siphon hose into fuel filler neck and
push it into the tank.
(4) Drain fuel tank dry into holding tank or a
properly labeledGASOLINEsafety container.
(5) Raise vehicle on hoist and support.
(6) Use a transmission jack to support fuel tank.
Remove bolts from fuel tank straps.
(7) Lower tank slightly.
(8) Disconnect the fuel filler vent tube. Squeeze
tabs and pull apart (Fig. 16).
(9) Disconnect the fuel fill hose at the fuel tank
filler metal tubeNOT AT THE FUEL TANK(Fig.
16).
(10) Disconnect fuel line and vapor line at the
front of the fuel tank.
The fuel pump module electrical connector
has a retainer that locks it in place.
(11) Slide fuel pump module electrical connector
lock to unlock (Fig. 17).
(12) Push down on connector retainer (Fig. 18) and
pull connector off module.
(13) Lower tank from vehicle. Remove fuel filler
vent tube from frame (Fig. 19).
INSTALLATION
(1) Position fuel tank on transmission jack. Con-
nect rollover valve hose. Connect fuel filler tube vent
hose and tighten clamp.
(2) Raise tank into position and carefully work
filler metal tube into the rubber hose on fuel tank. A
light coating of clean engine oil on the tube end may
be used to aid assembly.
(3) Feed filler vent line thru frame rail. Careful
not to cross lines.
Fig. 15 Fuel Tank
1 - ROLLOVER VALVE
2 - FUEL FILLER INLET
3 - ROLLOVER VALVE
4 - GROUND STRAP
5 - FUEL FILTER
6 - FUEL PUMP MODULEFig. 16 FUEL FILLER AND VENT TUBE
1 - Filler Tube
2 - Vent Tube
Fig. 17 Fuel Line Retainers and Pump Connector
Lock
1 - PUSH
2 - CONNECTOR LOCK
3 - QUICK CONNECT RETAINERS
RSFUEL DELIVERY14-11
FUEL TANK (Continued)
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(4) Tighten strap bolts to 54 N´m (40 ft. lbs.)
torque. Tighten T strap bolt to 28.2 N´m (250 in.
lbs.). Remove transmission jack.
(5) Tighten filler hose clamp to 3.3 N´m (30 in.
lbs.).
CAUTION: Ensure straps are not twisted or bent
before or after tightening strap nuts.
(6) Connect fuel pump/module electrical connector.
Place retainer in locked position.
(7) Lubricate the fuel supply line with clean 30
weight engine oil, install the quick connect fuel fit-ting. Refer to Tube/Fitting Assembly in the Fuel
Delivery section of this section.
(8) Connect the control vapor line at rear of tank.
(9) Attach filler vent line to filler tube. Pull on
connector to make sure of connection.
(10) Fill fuel tank, replace cap, and connect bat-
tery negative cable.
(11) Use the DRBIIItscan tool to pressurize the
fuel system. Check for leaks.
FUEL TANK FILLER TUBE
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the 3 screws at the filler door.
(3) Raise and support vehicle
(4) Remove the left rear tire.
(5) Remove the splash shield (Fig. 20) or (Fig. 21).
(6) Remove the canister from filler tube (Fig. 22).
(7) Disconnect the vent at the top of the filler tube.
(8) Remove the ground strap.
(9) Remove filler tube at tank.
INSTALLATION
(1) Install filler tube to tank (Fig. 20).
(2) Install the ground strap.
(3) Connect the vent at the top of the filler tube.
(4) Install the 3 screws at the filler door.
Fig. 18 Pump Module Connector Retainer and Lock
1 - PUSH DOWN ON RETAINER
2 - CONNECTOR LOCK
Fig. 19 VENT HOSE
Fig. 20 FUEL FILLER TUBE AND VENT TUBE (RG)
14 - 12 FUEL DELIVERYRS
FUEL TANK (Continued)
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(5) Install the canister from filler tube (Fig. 22).
(6) Install the splash shield.
(7) Install the left rear tire.
(8) lower vehicle.
(9) Connect the negative battery cable.
INLET FILTER
REMOVAL
(1) Remove fuel pump module. Refer to Fuel Pump
Module Removal in this section.
(2) Using a thin straight blade screwdriver, pry
back the locking tabs on fuel pump reservoir and
remove the strainer (Fig. 23).
(3) Remove strainer O-ring from the fuel pump
reservoir body.
(4) Remove any contaminants in the fuel tank by
washing the inside of the fuel tank.
INSTALLATION
(1) Lubricate the strainer O-ring with clean engine
oil.
(2) Insert strainer O-ring into outlet of strainer so
that it sits evenly on the step inside the outlet.
(3) Push strainer onto the inlet of the fuel pump
reservoir body. Make sure the locking tabs on the
reservoir body lock over the locking tangs on the
strainer.
(4) Install fuel pump module. Refer to Fuel Pump
Module Installation in this section.
QUICK CONNECT FITTING
STANDARD PROCEDURE - QUICK-CONNECT
FITTINGS
REMOVAL
When disconnecting a quick-connect fitting, the
retainer will remain on the fuel tube nipple.
Fig. 21 FUEL FILLER TUBE (RS)
Fig. 22 FUEL TUBE VENT CANISTER
Fig. 23 Inlet
1 - TABS
2 - INLET STRAINER
RSFUEL DELIVERY14-13
FUEL TANK FILLER TUBE (Continued)
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