Chrysler Full-Size Trucks 1989-1996 Repair Guide

Fuel Injector

Print

REMOVAL & INSTALLATION



See Figures 1, 2 and 3

  1. Remove the air cleaner assembly.
  2.  
  3. Relieve the fuel system pressure as previously described in this section.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Remove the injector cap hold-down on the dual point TBI system

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the fuel pressure regulator.
  4.  
  5. Remove the Torx® screw holding down the injector cap.
  6.  



Click image to see an enlarged view

Fig. Fig. 2: A small screwdriver can be used to carefully pry the injector upward



Click image to see an enlarged view

Fig. Fig. 3: When loose, remove the injector

  1. With two small prytools, lift the cap off the injector using the slots provided.
  2.  
  3. Using a small prytool placed in the hole in the front of the electrical connector, gently pry the injector from pod.
  4.  
  5. Make sure the injector lower O-ring has been removed from the pod.
  6.  

To install:
  1. Place a new lower O-ring on the injector and a new O-ring on the injector cap. The injector will have the upper O-ring already installed.
  2.  
  3. Put the injector cap on the injector. (Injector and cap are keyed). The cap should sit on the injector without interference. Apply a light coating of castor oil or petroleum jelly on the O-rings. Place the assembly in the pod.
  4.  
  5. Rotate the cap and injector to line up the attachment hole.
  6.  
  7. Push down on the cap until it contacts the injector pod.
  8.  
  9. Install the Torx® screw and tighten it to 35-45 inch lbs. (4-5 Nm).
  10.  
  11. Install the fuel pressure regulator.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Test for leaks using Mopar® ATM tester C-4805, or equivalent. With the ignition in the RUN position depress the tester button. This will activate the pump and pressurize the system. Check for leaks.
  16.  
  17. Reinstall the air cleaner assembly.
  18.  

 
label.common.footer.alt.autozoneLogo