Injector(S), Fuel: Installation
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.
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.
DO NOT use a brush to clean around the injector nozzle (4). DO NOT lubricate area around injector nozzle. The injector may become restricted with debris.
Be sure a NEW copper washer (3) and O-ring seal (2) is installed on the injector before installing in cylinder head.
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 seal (2) on the fuel injector.NOTE:
Use care not to get any grease on injector nozzle.
- Lubricate the injector body with Mopar® - Nickel Antisieze Compound, or Molikote Anti-Fretting Paste.
- Remove the protective caps from fuel injector and cylinder head.
- Using a new copper sealing washer (3), install fuel injector into cylinder head.
- Install the fuel injector (1), injector clamp (3), and bolt (2). Tighten bolt (2) to 28 N.m (21 ft. lbs.).NOTE:
The fuel tubes are a one time only use and must be replaced anytime they have been removed.
- Remove the protective caps and install
NEW
fuel tubes (2). Tighten fuel tubes to:
- Fuel tube at fuel rail 19 N.m (168 in. lbs.).
- Fuel tube at fuel injector 25 N.m (18 ft. lbs.).
- Attach the fuel return line to bracket (2) and install the fuel return line (3) and push down on each lock retaining tab (1) to lock in place.
- Position the wire harness (2) and connect the fuel injector wire harness connector (1).
- Connect the negative battery cable.
- Perform the injector classification procedure with a diagnostic scan tool. Refer to INJECTOR(S), FUEL, STANDARD PROCEDURE .
- Start the engine and inspect for fuel leaks.
- Install the engine cover.