Dodge Neon / Neon SRT-4. Manual — part 282
(6) Lower vehicle.
(7) Fill fuel tank. Check for leaks.
FUEL RAIL
DESCRIPTION
The fuel rail supplies the necessary fuel to each
individual fuel injector and is mounted to the intake
manifold (Fig. 15).
OPERATION
The fuel pressure regulator is no longer mounted
to the fuel rail on any engine. It is now located on
the fuel tank mounted fuel pump module. Refer to
Fuel Filter/Fuel Pressure Regulator in the Fuel
Delivery System section of this group for information.
The fuel rail is not repairable.
REMOVAL
REMOVAL - 4 CYLINDER
(1) Disconnect negative cable from battery.
(2) Release fuel system pressure. Refer to Fuel
System Pressure Release procedure in this section.
(3) Disconnect fuel supply tube from rail. Refer to
Quick-Connect Fittings in the Fuel Delivery section
of this group.
(4) Disconnect electrical connectors from fuel injec-
tors (Fig. 16), refer to the fuel injector connector sec-
tion for electrical connector removal.
(5) Remove fuel rail mounting screws.
(6) Lift rail off of intake manifold. Cover the fuel
injector openings in the intake manifold.
(7) Remove fuel injector retainer (Fig. 17).
(8) Pull injector out of fuel rail. Replace fuel injec-
tor O-rings (Fig. 18).
REMOVAL - 1.6 L
(1) Disconnect the negative battery cable.
(2) Release the fuel pressure, refer to the fuel
pressure release procedure in this section.
(3) Disconnect the negative battery cable.
(4) Remove the fuel line from the fuel rail (Fig.
19).
(5) Disconnect the electrical connector from the
fuel injectors (Fig. 20).
(6) Remove the electrical harness from the fuel
rail.
(7) Remove the 2 bolts for the fuel rail (Fig. 21).
(8) Remove the fuel rail from vehicle.
Fig. 15 Fuel Rail
Fig. 16 Fuel Rail and Injectors
1 - FUEL SUPPLY LINE
2 - FUEL LINE QUICK-CONNECTS
3 - IGNITION COIL
4 - FUEL RAIL
5 - FUEL INJECTOR
Fig. 17 Fuel Injector Retainer
1 - RETAINER
2 - FUEL RAIL
3 - FUEL INJECTOR
14 - 10
FUEL DELIVERY
PL/SRT-4
FUEL PUMP MODULE (Continued)
(9) Remove the fuel injectors from the rail.
INSTALLATION
INSTALLATION - 4 CYLINDER
(1) Apply a light coating of clean engine oil to the
upper O-ring.
(2) Install injector in cup on fuel rail.
(3) Install retaining clip.
(4) Apply a light coating of clean engine oil to the
O-ring on the nozzle end of each injector.
(5) Insert fuel injector nozzles into openings in
intake manifold. Seat the injectors in place. Tighten
fuel rail mounting screws to 22.5 N·m ± 3 N·m
(200±30 in. lbs.).
(6) Attach electrical connectors to fuel injectors,
refer to the fuel injector connector section for electri-
cal connector installation.
(7) Connect fuel supply tube to fuel rail. Refer to
Quick Connect Fittings in the Fuel Delivery Section
of this Group.
INSTALLATION - 1.6L
(1) Install fuel injectors to the fuel rail.
(2) Install the fuel rail to vehicle.
(3) Install fuel rail (Fig. 21) and tighten bolts to
22.5 ±3 N·m (200 ±30 in. lbs.).
(4) Connect the fuel injector electrical connectors
(Fig. 20).
(5) Install electrical harness to fuel rail.
Fig. 18 Fuel Injector O-Rings
1 - FUEL INJECTOR
2 - NOZZLE
3 - TOP (FUEL ENTRY)
Fig. 19 FUEL LINE CONNECTION
Fig. 20 FUEL INJECTOR CONNECTOR
Fig. 21 FUEL RAIL
PL/SRT-4
FUEL DELIVERY
14 - 11
FUEL RAIL (Continued)
(6) Connect the fuel line (Fig. 19).
(7) Connect the negative battery cable.
FUEL TANK
DESCRIPTION
The fuel tank is constructed of a plastic material.
Its main functions are for fuel storage and for place-
ment 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 con-
trol 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 con-
nections.
All models are equipped with either one or two
check valves mounted into the top of the fuel tank (or
pump module).
An evaporation control system is connected to the
check valve(s)/control valve(Refer to 25 - EMIS-
SIONS
CONTROL/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 evap-
orates 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 addi-
tion, 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 Con-
trol 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
(1) Perform fuel system pressure release, refer to
the fuel system pressure release procedure in this
section.
(2) Disconnect the negative battery cable (Fig. 22).
(3) Raise and support vehicle on hoist.
(4) Disconnect vapor line from EVAP canister tube.
(5) Remove EVAP canister (Fig. 23).
(6) Drain fuel tank. Remove the drain port cap and
remove fuel. Drain fuel tank into holding tank or a
properly labeled Gasoline safety container. Reinstall
drain port cap when done draining fuel (Fig. 24).
(7) Disconnect fuel pump module electrical connec-
tor and ground wire (Fig. 25).
(8) Disconnect the fuel tube from Fuel Filter/Reg-
ulator. Refer to Quick Connect Fittings in the Fuel
Delivery section of this group.
(9) Disconnect fuel filler tube and filler vent tube
from filler hose at fuel tank.
(10) Support tank with transmission jack. Loosen
tank mounting straps and lower tank slightly.
(11) Remove tank mounting straps and lower tank.
Fig. 22 Battery Cable
Fig. 23 EVAP Canister
14 - 12
FUEL DELIVERY
PL/SRT-4
FUEL RAIL (Continued)
INSTALLATION
(1) Position fuel tank on transmission jack.
(2) Raise tank into position.
(3) Tighten fuel tank strap nuts to 22.5 N·m (200
in. lbs.) torque. Remove transmission jack. Ensure
straps are not twisted or bent.
(4) Connect fuel filler tube tank inlet nipple.
Tighten clamp.
(5) Connect EVAP vent hose.
(6) Attach fuel tubes to pump module and chassis
fuel tube. Refer to Quick Connect Fittings in the Fuel
Delivery section of this Group.
(7) Attach electrical connector and ground wire to
fuel pump module.
(8) Install vapor lines to EVAP canister.
(9) Install EVAP canister.
(10) Lower vehicle.
(11) Fill fuel tank, install filler cap, and connect
battery cable.
(12) Use the DRB scan tool ASD Fuel System Test
to pressurize the fuel system. Check for leaks.
FUEL TANK FILLER TUBE
REMOVAL
(1) Loosen fuel filler tube cap.
(2) Remove fuel filler neck screws (Fig. 26).
(3) Raise and support vehicle.
(4) Remove splash shield from wheel well.
(5) Disconnect fuel fill vapor tube.
(6) Disconnect fuel filler tube from fuel tank.
(7) Remove groundstrap from body.
(8) Remove filler neck (Fig. 27).
INSTALLATION
(1) Install filler tube.
(2) Install fuel filler neck screws and plastic filler
cup.
(3) Connect fuel fill vapor tube.
(4) Connect fuel filler tube to fuel tank. Tighten
clamp.
(5) Connect ground strap to body.
(6) Lower vehicle.
(7) Install fuel filler tube cap.
Fig. 24 Fuel Tank
Fig. 25 Pump Module Electrical Connector
1 - ELECTRICAL CONNECTOR
2 - FUEL LINE
Fig. 26 Fuel Filler Neck
PL/SRT-4
FUEL DELIVERY
14 - 13
FUEL TANK (Continued)
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