Chrysler 4591986AA Injector-Fuel

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Relieve fuel system pressure and disconnect battery cable. Remove air intake duct, upper intake manifold, and fuel rail mounting nuts/bolts. Discard O-rings and install new ones with clean engine oil. Install injectors into fuel rail and activate fuel pump. Check for fuel leakage.

Start the engine and check for leaks at the quick-connect fitting and the upper end of each injector.

Discard the O-rings, and install new O-rings lubricated with clean engine oil. Install the injectors into the fuel rail. After installation, activate the fuel pump by turning the ignition switch to ON without operating the starter. Repeat this step two or three times and check for fuel leakage.

Coat the new O-rings with clean engine oil and install them on the injectors. Install the injectors into the fuel rail and secure with the injector clips. Guide the injectors/fuel rail assembly into the injector bores on the intake manifold and tighten the fuel rail mounting bolts. After installation, turn the ignition switch to On to activate the fuel pump and check for fuel leakage.

Disconnect the negative battery cable. If working on a V6 engine, remove the upper intake manifold or the air intake tube/resonator for a 2015 and later 2.4L engine.

Replace it.

Remove the fuel rail assembly and place the fuel rail assembly on a clean work surface so the fuel injectors are accessible. Remove the injector lock ring from the fuel rail and injector by prying it off with a small screwdriver. Pull the injector straight out of the receiver cup. Inspect the injector O-rings for damage. Replace them with new ones if necessary (Push the new O-ring over the tip of the injector and into the groove Insert a small screwdriver under the 0-ring and pry it off - be careful not to damage the injector tip). Prior to installation, lubricate the O-rings with a light film of clean engine oil. Push the top of the injector straight into the fuel rail receiver cup, taking care not to damage the O-ring. Slide the open end of the injector clip into the top slot of the injector, onto the receiver cup ridge and into the side slots of the clip. Install the fuel rail.

Start by relieving the fuel pressure and disconnecting the battery cable. Remove the air intake duct/resonator from the air filter housing and throttle body. Use a special tool to remove the fuel line from the fuel rail and label and remove any interfering vacuum hoses or electrical wiring and connectors. On 2.4L four-cylinder engines, drain the coolant, remove the thermostat, injector wiring, PCV valve, and intake manifold bolts. On V6 engines, disconnect electrical connectors from the throttle body, remove ignition coils, and intake manifold (4.0L engines). Clean around the injectors and remove the fuel rail mounting nuts/bolts, then gently rock the fuel rail to remove it along with the injectors as an assembly.

Discard the O-rings, and install new O-rings lubricated with clean engine oil. Install the injectors into the fuel rail. After installation, activate the fuel pump by turning the ignition switch to ON without operating the starter. Repeat this step two or three times and check for fuel leakage.