INJECTOR(S), Fuel: Installation: Installation

CAUTION:

Due to the complexity of the fuel injection system used on this engine, refer to the Diesel Engine Diagnostics, and service any fuel system DTCs prior to replacing any fuel injectors. If no DTCs are present, refer to the Diesel Engine Diagnostic Test for Lack of Engine Power, and perform all steps as directed prior to replacing any fuel injectors.

CAUTION:

Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only. DO NOT use any lubricating or sliding agents that contain water.

Fig 1: Identifying Injector Nozzle & Copper Washer/Seal

Courtesy of CHRYSLER LLC

NOTE:

DO NOT use a brush to clean around the injector nozzle (2). DO NOT lubricate area around injector nozzle. The injector may become restricted with debris.

NOTE:

Be sure a new copper washer/seal (3) is installed on end of injector and the old seal is removed, before installing in cylinder head.

NOTE:

No force should be used in installing the fuel injector. Do not apply any pressure to the electrical connector or the fuel return port during the installation process.

Install a new O-ring on the fuel injector return nipple.
NOTE:
Use care not to get any grease on injector nozzle.
Lubricate the injector body with Lubriplate all purpose white grease.
Using a new copper sealing washer (3), install fuel injector into cylinder head.

Fig 2: Identifying Injector, Mounting Clamp, Mounting Bolt & Washer
Courtesy of CHRYSLER LLC
Install fuel injector (4), retainer clamp (1), washer (3) and a new bolt (2). Tighten clamp bolt (2) to 33 N.m (24 ft. lbs.).
Remove the protective caps and install fuel injector high-pressure tubes. Refer to TUBE(S), Fuel, Installation .

Fig 3: Lifting Lock Buttons
Courtesy of CHRYSLER LLC

NOTE:
Be sure lock buttons (1) are in up position before positioning.
Position female fittings on fuel return line to male fittings at each fuel injector.

Fig 4: Pushing Each Lock Button Down To Secure Fuel Return Line To Each Fuel Injector
Courtesy of CHRYSLER LLC
After positioning, push down on each lock tab (1) to secure fuel return line to each fuel injector.

Fig 5: Injector Connector
Courtesy of CHRYSLER LLC
Connect the fuel injector harness connector (1).
Connect the negative battery cable.
Perform the injector classification procedure with a diagnostic scan tool.
Start the engine and allow to warm. Turn off the ignition switch and inspect for fuel leaks.
Install the engine silencer (2) and securely tighten fasteners.
Install engine cover.