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

CAUTION: Due to the complexity of the fuel injection system used on this engine, service any fuel system DTCs prior to replacing any fuel injectors. If no DTCs are present, refer to the appropriate 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.

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.

1. Install fuel injector into cylinder head with new seal.
   Fig 2: Identifying Injector, Mounting Clamp, Mounting Bolt & Washer

   Courtesy of CHRYSLER LLC
2. Install fuel injector retainer clamp (1), washer (3) and bolt (2). Tighten clamp bolt (2) to 33 N.m (24 ft. lbs.) torque.
3. Connect electrical connector to fuel injector.
4. Install fuel injector high-pressure lines. Refer to INSTALLATION  .
   Fig 3: Lifting Lock Buttons

   Courtesy of CHRYSLER LLC
5. Position female fittings on fuel return line to male fittings at each fuel injector. Be sure lock buttons (1) are in up position before positioning. 
   Fig 4: Pushing Each Lock Button Down To Secure Fuel Return Line To Each Fuel Injector

   Courtesy of CHRYSLER LLC
6. After positioning, push each lock button (1) down to secure fuel return line to each fuel injector.
7. Connect each fuel injector electrical connector.
8. Connect negative battery cable.
9. Perform the injector classification procedure with a diagnostic scan tool.
10. Start the engine and allow to warm. Turn off the ignition switch  and inspect for fuel leaks.
11. Install engine dress-up cover.