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Home >> Chrysler >> 2011 >> 300 C, 4WD >> Repair and Diagnosis >> External Pages >> Different car >> Section 395 (Fuel System - 2500 Hd & 3500 Hd) >> Fuel Injection, 6.7L Diesel >> Injector(S), Fuel >> Installation >> Installation

Injector(S), Fuel: Installation: Installation

WARNING: This page is about a different car, the 2013 RAM 3500 HD and 2013 RAM 2500 HD. However, it is still accessible from the selected car via links, so may be relevant.
  1. Inspect fuel injector : 
    • Look for burrs on injector inlet.
    • Check nozzle holes for hole erosion or plugging.
    • Inspect end of nozzle for burrs or rough machine marks.
    • Look for cracks at nozzle end.
    • If any of these conditions occur, replace injector.
  2. Inspect high-pressure fuel injector connector for : 
    • Damaged tip.
    • Loose of missing alignment pin.
    • Cut or missing O-ring.
  3. Thoroughly clean fuel injector cylinder head bore. Blow out bore hole with compressed air.
    Fig 1: Measuring Injector Sealing Washer (Shim)
    GC0108842Courtesy of CHRYSLER GROUP, LLC
  4. The bottom of fuel injector is sealed to cylinder head bore with a copper sealing washer (shim) (1) of a certain thickness. A new shim (1) with correct thickness must always be re-installed after removing injector. Measure thickness of injector shim (1). Shim Thickness: 1.5 mm (.060") 
  5. Install new shim (1) (washer) to bottom of injector. Apply light coating of clean engine oil to washer. This will keep washer in place during installation.
  6. Install new O-ring to fuel injector. Apply small amount of clean engine oil to O-ring and injector bore.
    Fig 2: Fuel Injector & Mounting Bolts
    GC0108775Courtesy of CHRYSLER GROUP, LLC
  7. Install injector into cylinder head with male (high-pressure) connector port facing the intake manifold. Push down on fuel injector mounting flange to engage O-ring and seat injector.
    Fig 3: Removing/Installing Fuel Line Shield, High Pressure Fuel Lines, HPC Connector Tube, Fuel Injectors & Bolts
    GC0155209Courtesy of CHRYSLER GROUP, LLC
  8. Tightening Sequence:
    • Install fuel injector hold-down clamp (mounting flange) bolts. Be sure the clamp is perpendicular to the injector body. Do a preliminary tightening of these bolts to 5 N.m (44 in. lbs.). This preliminary tightening insures the fuel injector is seated and centered. 
    • After tightening, relieve bolt torque, but leave both bolts threaded in place.
    • Install the fuel injector connector (14) and fuel injector connector nut (13). Do a preliminary tightening of nut (12) to 15 N.m (133 in. lbs.).
    • Alternately tighten injector hold-down bolts to 8 N.m (71 in. lbs.).
    • Do a final tightening of the fuel injector connector nut (13). Tighten to 55 N.m (41 ft. lbs.).
  9. Install the fuel tubes. Refer to TUBE(S), FUEL, INSTALLATION .
    Fig 4: Rocker Housing Mounting Bolt
    GC0137160Courtesy of CHRYSLER GROUP, LLC
  10. Install the necessary rocker housing mounting bolt (1) and tighten to 24 N.m (18 ft. lbs.).
    Fig 5: Fuel Injector Wiring Harness Components
    GC0108840Courtesy of CHRYSLER GROUP, LLC
  11. Install the cylinder head cover gasket.
  12. Connect fuel injector solenoid wires and nuts (1) to top of injectors. Tighten connector nuts to 1.50 N.m (13 in. lbs.). Be very careful not to overtighten these nuts as damage to fuel injector will occur. 
  13. Install the intake and exhaust rocker arm assembly. Refer to ROCKER ARM, VALVE, INSTALLATION, 6.7L .
  14. Set exhaust valve lash. Refer to STANDARD PROCEDURE .
    Fig 6: Injector Harness Connectors
    GC0155340Courtesy of CHRYSLER GROUP, LLC
  15. Connect both fuel injector harness connectors (3).
  16. Install cylinder head cover. Refer to COVER(S), CYLINDER HEAD, INSTALLATION, 6.7L .
  17. Connect both negative battery cables.
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