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leaking fuel rail fix

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Old 02-26-2012, 03:42 PM
blknblu blknblu is offline
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Default leaking fuel rail fix

leaking fuel rail - 4th gen 2001 3.8

For several month now, I've detected a strong smell of gas under the hood. After watching it for a couple of days, I noticed gas dripping out of the cap on the fuel rail. I found a post where someone removed the cap and replaced the internal o-ring with an o-ring from the fuel injectors. I did the fix, and it is not leaking. The best part was I did not have to remove the fuel rail. You will need to go to the auto store and ask for fuel injector o-rings for the van. Mine came in a package of 2 for 2.39.

1) Relieve gas pressure:
Remove the fuel pump relay and start the van, running it until it dies. (This is in the fuse box)
disconnect the battery (just being cautious)

2) Move power steering reservoir:
Loosen the bolts for the reservoir , lift it slightly and push it to the side.
(There are 2 accessible bolts on the top, and one nut underneath that you just have to loosen)

3) Remove cap:
Gently pry the cap off, use the bracket for the power steering for leverage.

4) Prepare cap:
Remove old o-ring
Bend the tangs back on the cap so it will fit tightly when you re-install it.
Lubricate the o-ring with some fresh oil and put it on the cap.

5) Install cap:
Put cap over the hole making sure it is centered.
Gently tap on the end until it slides back in the hole and is seated properly.

6) Check for leaks:
Re-connect the battery.
Put back the fuel pump relay and start van.
Check for leaks.

7) Put everything back together:
Move power steering reservoir back and tighten bolts.

That's it, it is pretty simple to do as long as you are careful.
Not once did the CEL come on.
This cap is not for a test port, it looks more like a pressure relief port.
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Last edited by blknblu; 02-26-2012 at 05:33 PM..
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Old 02-26-2012, 05:16 PM
steak59 steak59 is offline
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what year is your van? there is a Recall for this on the late 90s van.
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Old 02-26-2012, 05:33 PM
blknblu blknblu is offline
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This is for 4th gen 2001 Chrysler T&C 3.8, same as the Dodge Caravans.
I am aware of the recall for the 3rd generation vans. This is for the 4th generation vans.
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Old 04-04-2013, 01:28 PM
clt5050 clt5050 is offline
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Angry

1995 dodge caravan 3.3
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Old 04-04-2013, 02:07 PM
clt5050 clt5050 is offline
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01/1995
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Old 04-04-2013, 02:07 PM
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