Injector(S), Fuel: Installation: Installation

WARNING: This page is about a different car, the 2016 Dodge Journey and 2015 Dodge Journey. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION:

Pay close attention to the following points when installing fuel injectors.

Blow out injector recesses, clean again with a non-woven cloth and then cover over. Fiber residues from woven cloths ARE NOT permissible.
Carefully carry out a visual inspection of the sealing surfaces of the injector recesses.
The length of the round brush can be adjusted and should be approximately 3 mm for cleaning the seal seat. Optimal cleaning is achieved only if a brush with a flat surface is used. If necessary the surface of the brush can be ground flat on a grinding stone.
ALWAYS replace the seals which seal off the injectors at the cylinder head to the combustion chamber. It is important that no grease gets onto the seal. Any impurities on the seal, on the sealing surfaces at the injector and cylinder head as a result of combustion residue or similar are absolutely not permissible.
The nuts attaching the injectors must always be replaced.
The tip of the injector nozzle MUST NOT be cleaned with a wire brush. Use a non-woven cloth.
Clean entire injector with a non-woven cloth.
Fiber residues from a woven cloths are not permissible.

Fig 1: Fuel Injector & Retaining Clamp

Courtesy of CHRYSLER GROUP, LLC

NOTE:

If a new fuel injector is being installed, there is a nine digit alphanumeric code on the injector that needs to be entered into the PCM using the scan tool.

Clean injectors and recesses. Refer to INJECTOR(S), FUEL, STANDARD PROCEDURE .
Coat injector body with clean diesel fuel and install new sealing washers.
Install the fuel injector (3) and retaining claw (2) to its original location as noted during the removal process and apply downward pressure to seat it. Install nut (1) and tighten to 28 N.m (21 ft. lbs.).

Fig 2: Fuel Injector Wire Harness Connector & Bolt
Courtesy of CHRYSLER GROUP, LLC
Connect the Camshaft Position Sensor (CMP) wire harness connector.
Position the engine wire harness and connect all four fuel injector wire harness connectors (1).
Install and securely tighten the seven bolts (2) securing the engine wire harness.

Fig 3: Turbocharger Heat Shield & Fasteners
Courtesy of CHRYSLER GROUP, LLC
Install the lower turbocharger heat shield (2).
- Tighten bolts (1) to 12 N.m (106 in. lbs.).
- Tighten nut (3) to 8 N.m (71 in. lbs.).
Attach the exhaust manifold exhaust temperature sensor wire harness to the lower turbocharger heat shield.

Fig 4: Upper Turbocharger Heat Shield & Bolts
Courtesy of CHRYSLER GROUP, LLC
Install the upper turbocharger heat shield (2). Tighten the bolts (1) to 12 N.m (106 in. lbs.).

Fig 5: Oxygen Sensor Wire Harness Connector
Courtesy of CHRYSLER GROUP, LLC
Attach the oxygen sensor wire harness connector (2) to the bracket (3) and connect the oxygen sensor wire harness connector (1).

Fig 6: High Pressure Fuel Tubes
Courtesy of CHRYSLER GROUP, LLC
Install new fuel tubes (2). Refer to TUBE(S), FUEL, HIGH PRESSURE, INSTALLATION .

Fig 7: Fuel Return Lines & Injectors
Courtesy of CHRYSLER GROUP, LLC
Install the fuel return lines (1) to the fuel injectors (2) and install the retaining clips.

Fig 8: Engine Cover
Courtesy of CHRYSLER GROUP, LLC
Connect the negative battery cable.
Using a diagnostic scan tool, entered the fuel injector nine digit alphanumeric code into the PCM.
Start the engine and check for leaks.
Install the engine cover (1).