Dodge Caliber. Manual

10. Remove fuel injectors from fuel rail.

INSTALLATION

1. Apply a light coating of clean engine oil to the

O-ring on the nozzle end of each injector.

2. Install the fuel injectors to the fuel rail.

3. Install injector into cup of fuel rail.

4. Install retaining clip and check to ensure injector is

properly captured.

Fuel rail assembly.

FUEL DELIVERY

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8. Connect and lock the electrical connectors to the

fuel injectors.

9. Connect the fuel line to the fuel rail. Refer to Quick

Connect Fittings in the Fuel Delivery Section of this
Group.

10. Connect the negative battery cable.

11. Use the San Tool Fuel System Test to pressurize

the fuel system. Check for leaks.

FUEL DELIVERY

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FUEL TANK

DESCRIPTION

The fuel tank is constructed of a plastic material. Its main functions are for fuel storage and for placement 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 control 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 connections.

All models are equipped with either one or two check valves mounted into the top of the fuel tank (or pump mod-
ule).

An evaporation control system is connected to the check valve(s)/control valve (Refer to 25 - EMISSIONS CON-
TROL/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 evaporates 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 addition, 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 Control 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.

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. This may result in
personal injury or death.

1. Release fuel system pressure. Refer to Fuel Pres-

sure Release Procedure in this section.

2. Remove the air cleaner lid, disconnect the inlet air

temperature sensor and makeup air hose.

3. Remove the negative battery cable.

4. Remove the rear seat cushion.

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FUEL DELIVERY

Dodge Caliber. Manual - part 1139