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Fuel Injection - 2.8L Diesel: Injector-Fuel: Removal: Removal

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.
  1. Disconnect negative battery cable at battery. Isolate end of cable.
  2. Remove dress-up cover from top of engine.
  3. Remove the high-pressure fuel lines from fuel rail to fuel injectors. Refer to REMOVAL  .
    Fig 1: Fuel Injectors - 2.8L Diesel
    GC0062739Courtesy of CHRYSLER LLC
  4. Locate common fuel return line (1).
    Fig 2: Lifting Lock Buttons
    GC0062760Courtesy of CHRYSLER LLC
  5. Disconnect electrical connector at top of injector(s).
    NOTE: The injector common fuel return line is connected to the low pressure fuel circuit (5 bar/72 psi).
  6. A lock button (1) is used to secure the common fuel return line to each fuel injector. Use your fingers to lift all four lock buttons (1) up. After unlocking all four buttons, lift fuel return line assembly up for removal.
    Fig 3: Identifying Injector, Mounting Clamp, Mounting Bolt & Washer
    GC0062761Courtesy of CHRYSLER LLC
  7. Remove injector mounting bolt (2) and washer (3).
  8. Remove injector mounting clamp (1).
  9. Using compressed air, thoroughly clean surface area in and around injector bore to prevent foreign material from falling into the injector bore after injector removal.
  10. Using your hand, pull fuel injector straight up from cylinder head for removal.
    Fig 4: Installing Special Fuel Injector Removal Tool #9552 To Top Of Fuel Injector
    GC0062762Courtesy of CHRYSLER LLC
  11. If injector can't be removed by hand, install special fuel injector removal tool #9552 (2) to top of fuel injector.
    Fig 5: Installing Special Slide Hammer Tool #8941 Onto Special Tool #9552, Tightening Lock Nut & Removing Injector From Cylinder Head
    GC0062763Courtesy of CHRYSLER LLC
  12. Install special slide hammer tool #8941 (1) onto special tool #9552 (4). Tighten lock nut (2). Remove injector from cylinder head.
NOTE: DO NOT use a wire brush to clean the fuel injector or nozzle. Possible restriction of the injector needle may result.
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