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Home >> Dodge and Ram >> 1990 >> Caravan Base, 2.5 J, Standard >> Repair and Diagnosis >> Engine Performance >> Remove, Overhaul & Install >> Engine Controls - Remove/Install/Overhaul >> Removal & Installation >> Fuel Injector Rails (3.3L PFI Models) >> Installation
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Fuel Injector Rails (3.3L PFI Models): Installation

  1. Be sure injectors are seated into receiver cups on rail with lock rings in place. See FUEL INJECTOR (PFI MODELS) . Make sure injector holes are clean and all plugs have been removed. Replace "O" rings if damaged.
  2. Lubricate injector "O" rings with a drop of clean engine oil to ease installation. Push the tip of each injector into its port. Push entire assembly into place until injectors are seated in ports.
  3. Install 4 fuel rail attaching bolts and tighten to 17 ft. lbs. (22 N.m). Install fuel tube retaining bracket screw and tighten to 35 INCH lbs. (4 N.m). Reconnect cam sensor, coolant temperature sensor and engine temperature sensor.
  4. Reconnect fuel injector wiring harness to engine harness. Install fuel injector wiring harness wiring clips on alternator bracket and intake manifold water tube. Connect fuel pressure regulator vacuum line. Remove covering on lower intake manifold and clean surface.
  5. Place intake manifold gasket on lower manifold. Put upper manifold into place and install bolts finger tight. Install alternator bracket-to-intake manifold bolt and cylinder head-to-intake manifold strut bolts finger tight.
  6. Tighten upper-to-lower intake manifold bolts to 21 ft. lbs. (28 N.m) following torque sequence. See Fig 1. Tighten alternator bracket-to-intake manifold bolt to 40 ft. lbs. (54 N.m). Tighten cylinder head-to-intake manifold strut bolts to 40 ft. lbs. (54 N.m).
    Fig 1: Intake Manifold Bolt Torque Sequence (3.3L)
    G90H15609Courtesy of DAIMLERCHRYSLER CORP.
  7. Install ground strap. Reconnect MAP sensor, oxygen sensor and charge temperature sensor electrical connectors. Connect vacuum harness to intake plenum.
  8. Connect PCV system. Using a new gasket, connect EGR tube flanges to intake manifold and tighten to 17 ft. lbs. (22 N.m).
  9. Clip wiring harness into hole in throttle cable bracket. Connect wiring connectors to throttle position sensor and automatic idle speed sensor. Connect vacuum harness to throttle body.
  10. Install direct ignition system coils. See IGNITION COIL under IGNITION SYSTEMS. Tighten fasteners to 105 INCH lbs. (12 N.m). Install fuel hose quick connect fittings to fuel rail. Push each fitting onto rail until it clicks into place. Fuel supply fitting is 5/16" and fuel return fitting is 1/4".
  11. Install throttle cable. Install air cleaner and hose assembly. Connect negative battery cable. Pressure test system for leaks.
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