Chrysler 68060335AA 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.

A leaking fuel injector can cause fuel knock, poor acceleration, low fuel economy, rough idle and misfire. It is recommended to have any checks on diesel fuel injectors done by a dealer service department or qualified diesel repair facility, as injector tests require special high-pressure testing equipment and adapters. Removing and installing the injectors requires expensive special tools, making it not recommended to attempt this job at home. It is generally more cost-effective to have this job done by a dealer service department or diesel specialist.

Remove the upper intake manifold.

Start by relieving any pressure inside the fuel tank by removing the fuel tank filler neck cap. Then, relieve the fuel system pressure. Disconnect the cable from the negative terminal of the battery. Remove the air intake duct. Disconnect the electrical connector from the throttle body and remove the intake manifold bracket on 3.5L V6 engines. Remove the upper intake manifold. Disconnect the fuel supply line from the fuel rail using a special tool. Disconnect the electrical connectors from the fuel injectors and set the injector harness aside. Clean any debris from around the injectors. Remove the fuel rail mounting nuts/bolts. Gently rock the fuel rail and injectors to loosen them and remove the fuel rail and injectors as a single assembly. Remove the injectors from the fuel rail and discard the O-rings. Coat the new O-rings with clean engine oil and install them on the injectors. Install the injector retaining clip and insert each injector into its corresponding bore in the fuel rail. Clean the injector bores on the intake manifold. Guide the injectors/fuel rail assembly into the injector bores on the intake manifold and tighten the fuel rail mounting bolts securely. For V8 engines, follow similar steps but also remove the fuel supply line fitting from the right fuel rail. Disconnect the electrical connectors from all eight fuel injectors and remove the fuel rail mounting bolts. Carefully pull and wiggle the injectors to remove them from their mounting holes. Remove the injectors from the fuel rail, 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.

The injector bores on the intake manifold should be cleaned.

It is important to check for fuel line leaks before proceeding with any checks on diesel fuel injectors.

It is important to check for fuel line leaks before proceeding with any checks on diesel fuel injectors.

Remove the air intake duct and disconnect the fuel supply line. Label and disconnect any vacuum hoses and electrical connectors that may interfere with fuel rail removal. Remove the ignition coils and clean any debris around the injectors. Remove the fuel rail mounting bolts and gently rock the fuel rail to loosen the injectors. Remove the fuel rail and injectors as an assembly.

Remove the air intake duct and disconnect the fuel supply line. Label and disconnect any vacuum hoses and electrical connectors that may interfere with fuel rail removal. Remove the ignition coils and clean any debris around the injectors. Remove the fuel rail mounting bolts and gently rock the fuel rail to loosen the injectors. Remove the fuel rail and injectors as an assembly.