Chrysler Full-Size Vans 1967-1988 Repair Guide

Fuel Injector

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3

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Fig. Fig. 1: Removing the injector cap hold-down



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Fig. Fig. 2: Remove the fuel injector from the throttle body by gently prying it up



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Fig. Fig. 3: Inspect the O-rings on the injector for cracks or splits

  1. Remove the air cleaner assembly.
  2.  
  3. Perform the fuel system pressure release.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the fuel pressure regulator.
  8.  
  9. Remove the Torx® screw holding down the injector cap.
  10.  
  11. With two small screwdrivers, lift the cap off the injector using the slots provided.
  12.  
  13. Using a small screwdriver placed in the hole in the front of the electrical connector, gently pry the injector from pod.
  14.  
  15. Make sure the injector lower O-ring has been removed from the pod.
  16.  

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 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 torque it to 35-45 in. lbs.
  10.  
  11. Install the fuel pressure regulator.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Test for leaks using ATM tester C-4805 or equivalent. With the ignition in the RUN position depress the ATM button. This will activate the pump and pressurize the system. Check for leaks.
  16.  
  17. Reinstall the air cleaner assembly.
  18.  

 
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