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leaking fuel rail cap fix

83789 Views 67 Replies 22 Participants Last post by  atoman
First time posting,
I have a 2001 Chrysler Town Country with 3.8

For several months 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. (Same size) I did the fix, and it has not leaked since I replaced the o-ring. The best part was I did not have to remove the fuel rail. (A new one is pricey) 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 from NAPA.

Thse are the steps I took:

1) Relieve gas pressure from fuel injection rail:
Remove the fuel pump relay and start the van, running it until it dies. (The relay is in the fuse box)

2) disconnect the battery (just being cautious)

3) 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)

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

The pic with the blue o-ring is the original. (notice the erosion on it)

5) 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.

6) 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.

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

8) 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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Wanted to chime in and ask if any of you guys replaced the fuel-line coupler/jumper O-ring that is housed in the tee connection? My metal rail cap isn't leaking on my 01GC with 147k, but I was smelling gas in the engine compartment. After I cleaned the area including the coupler seals to the rail, I was leaking from the black cap on the flexline coupler. When I took off the cap (followed SOP for pressure), my O-ring was shredded and worn out. Seems like another Oring to keep an eye on if anyone ever turns that cap. I want to know what size you use since it is not a "serviceable" item and mine is trashed. I made a temp one today with another fluoroelastomer. Viton should be fine especially since lower temp than the fuel injector O-rings, right?

I am hoping that this explain why my van starts a little rough in the morning now (given that the pressure may be lower than normal with the slow leak).

Thanks, Mike
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