Fuel Rail Leak

Tiny
JRR4948
  • MEMBER
  • 2002 DODGE CARAVAN
  • 4 CYL
  • 2WD
  • AUTOMATIC
  • 160,000 MILES
4 cylinder 2.4L Dodge Caravan with Fuel Injection. 160,000 miles. The fuel rail has a port for what I think is used to measure pressure with a gauge that is similar to the stem of a tire for air. Then there is another steel tube w/cap that is protruding perpendicular to the rail in the middle of the rail. This points towards the front of the car under the manifold. I believe this is a pressure regulator? There are no wires or hoses attached. The cap can spin but I can not remove it. The gas leaks from this cap in a very slow drip for the first few minutes then it stops once the car has been driven for a few minutes. The injectors are fine and do not leak and the car runs very well. Do I Need to replace the entire rail or can I fix this part where the cap is. Is there an "O" ring here? Can the cap come off? Thank you!
Wednesday, January 21st, 2009 AT 9:15 PM

5 Replies

Tiny
TONE94SHADOW
  • MEMBER
  • 8 POSTS
If this is the port on the fuel rail that its leaking from. Its the fuel test port. it has a valve stem like the one used for your tires .it has a different o ring although. your pressure regulator i belive is in the sending unit.if not then it would be on the fuel rail and it would have a vacume hose atached to it https://www.2carpros.com/forum/automotive_pictures/308207_Graphic_1.jpg
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Monday, January 26th, 2009 AT 5:55 PM
Tiny
JRR4948
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  • 2 POSTS
Tone 94 thank you for the reply but it is not the valve stem port it is a pressure regulator. I took it apart and the "O" ring which is the exact "O" ring used on he injector where it attached to the rail was leaking.I relaced it and it is fine now. Thanks for your help
JR
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Tuesday, January 27th, 2009 AT 2:36 PM
Tiny
ZENRIDDLE
  • MEMBER
  • 1 POST
JR is correct. At right side end of fuel rail on my 2002 dodge caravan 3.3l there is a metal mushroom looking cap. My fuel leak was coming from there. That cap has 5 metal clips holding it onto fuel rail. Use a slim screwdriver to pry them clips outwards slightly. Pull up cap till it comes off. Inside is a blue fuel injector oring seal. Remove and replace. Replace blue oring onto cap. Wet oring with gasoline then push cap back on till it clips in. Use a needle nose plier to squeeze back clips onto connector. And leak is Gone. I have attached 2 pics below. Easy repair.
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Monday, October 1st, 2018 AT 12:34 PM
Tiny
MORGAN WRIGHT
  • MEMBER
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I had the same exact problem on my 2002 Chrysler T & C with a 3.8 engine. It leaked when the engine was cold and stopped when it warmed up. The mechanic looked at the part and called it a pressure regulator. I went to NAPA to get a new O-ring and the NAPA parts guide also called it a pressure regulator. So I guess that's what it is. I got the O-ring, same size O-ring the injectors use, and fixed it according to what Zenriddle said above. You DONT have to pull the fuel rail or intake manifold or anything like the other thread says. The fix described by zenriddle worked perfectly and I did it in 10 minutes. You just have to move the steering fluid reservoir out of the way and there is the pressure regulator. Only thing to worry about is, when you get the regulator apart about a quart (or more) of gasoline will squirt in your face so make sure you have lots of rags to catch it, and don't light any cigarettes. Once the squirting stops just replace the O-ring with the new one and you fixed the car for $3.00. It takes a lot of force to push the new O-ring in, I put a big wrench sideways across the regulator and pushed down with all my body weight (280) and even then I had to wiggle it to get it in. Once it was in, it was easy to bend the metal tabs back on it. No more leak!
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Wednesday, May 1st, 2019 AT 5:34 AM
Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
  • 47,347 POSTS
Great addition to this thread! Please feel free to help out whenever you are on the site :)

Cheers, Ken
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Wednesday, May 1st, 2019 AT 12:25 PM

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