How to Check for Fuel Delivery in a Dodge Caravanby Contributor; Updated November 07, 2017
How to Check for Fuel Delivery in a Dodge Caravan. The Dodge Caravan was introduced in the 1984 model year. The Grand Caravan, sporting a longer wheelbase, debuted in 1987. The Caravan is a four-door minivan with front wheel and four wheel drive, except in models with the optional stow-and-go seating. Check the Dodge Caravan's fuel delivery system if the engine does not start immediately, if it stalls or exhibits low power.
Disconnect the negative battery cable in Dodge Caravan vehicles produced in 2000 with 2.4L, 3.3L and 3.8L engines. Remove the cap from the pressure test port, located on the fuel rail. Put the open end of the fuel pressure release hose tool C-4799-1 into a container approved for fuel and put a shop towel under the port. Connect the other end of the hose to the pressure test port. Release the pressure, remove the hose and then replace the cap.
Relieve fuel system pressure in Dodge Caravan vehicles produced in 2000 and after. Disconnect the fuel pump relay from the power distribution center. Start the car and let the engine run until it stalls. Try to start it again and don't continue until the engine no longer runs at all. Turn the ignition switch to the "off" position.
Continue relieving the fuel delivery for a 3.0L engine produced in 2000. Disconnect the fuel injectors and attach one end of a jumper wire to an injector terminal located at the fuel injector harness connector. Attach the other end of the wire to the positive battery terminal. Secure one end of a second jumper wire to the remaining free injector terminal. Quickly touch the free end of the second jumper wire to the negative battery terminal.
Remove the vacuum line from the fuel pump pressure regulator and check for fuel. Refer to the owner's manual for the line's location. There shouldn't be any fuel in the line. If there is, the engine problems are likely caused by a faulty fuel pump pressure regulator, which means the fuel is flowing back into the lines rather than into the engine. If there is no fuel in the lines, reattach the vacuum line and continue with the fuel delivery diagnostic.
Reconnect the battery and twist off the fuel pressure test port cap and attach a fuel pressure test gauge. Turn the engine on and let it idle. Check the gauge. It needs to read between 44 and 54 pounds per square inch. Pressure that's too high or too low may mean the fuel pump is malfunctioning or that the fuel filter is clogged. Remove the pressure gauge.
Disconnect the negative battery cable again and relieve fuel system pressure again so you can remove the fuel filter to check for clogs.
Raise up the Dodge Caravan and use a transmission jack to support the fuel tank. Remove the fuel line, located at the front of the tank. Remove the ground strap, the straps at the inboard side of the tank and the front T-strap fastener. Lower the fuel tank approximately six inches and disconnect the fuel pump module from the remaining fuel lines. Remove the fuel filter and visually inspect it for clogs. Reinstall it if it's in good working condition. Replace it if it's clogged, or it's been more than one year or 47,000 miles since it was last replaced.
Install or reinstall the fuel filter by reversing the removal process listed in Step 5. Tighten the filter bolts to 40 inch pounds (4.5 Nm). Secure the tank straps to 40 foot pounds (54 Nm). Tighten the T-strap to 250 inch pounds (28 Nm). Start the engine and visually inspect the Caravan's fuel filter for leaks.