Chrysler Neon 1995-1999 Repair Guide

Fuel Injector(s)

Print

REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5 and 6

  1. Disconnect the negative battery cable.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove the fuel rail, as outlined later in this section.
  6.  
  7. Unfasten the fuel injector-to-rail retaining clip, then pull the fuel injector out of the rail.
  8.  



Click image to see an enlarged view

Fig. Fig. 1: Remove the injector-to-fuel rail retaining clip ...



Click image to see an enlarged view

Fig. Fig. 2: ... then pull the fuel injector up and out of the fuel rail



Click image to see an enlarged view

Fig. Fig. 3: Exploded view of the fuel injector and retaining clip

  1. Use a small awl to carefully remove the O-rings from each end of the injector. Discard the O-rings and replace with new ones during installation.
  2.  



Click image to see an enlarged view

Fig. Fig. 4: The fuel injector has O-rings at each end which must be replaced before installation



Click image to see an enlarged view

Fig. Fig. 5: Use an awl to carefully remove the O-ring from the top end of the fuel injector



Click image to see an enlarged view

Fig. Fig. 6: Don't forget to remove the O-ring from the bottom end of the injector

To install:
  1. Install new O-rings on each end of the injector.
  2.  
  3. Lightly coat the upper O-ring of the injector with clean engine oil.
  4.  
  5. Install the injector in the cup on the fuel rail, then secure with the retaining clip.
  6.  
  7. Install the fuel rail, as outlined later in this section.
  8.  
  9. Connect the negative battery cable.
  10.  

TESTING



See Figure 7

  1. Unplug the injector electrical connector.
  2.  
  3. Using an ohmmeter, test the injector resistance across the injector terminals. The reading should be approximately 12 ohms at 64°F (20°C).
  4.  



Click image to see an enlarged view

Fig. Fig. 7: Connect an ohmmeter to the fuel injector terminals and measure the resistance

  1. If the resistance falls outside specifications, replace the faulty injector.
  2.  
  3. If the resistance is within specifications, proceed with the testing.
  4.  

  1. Place a 12 volt test lamp across injector electrical connector terminals. Watch the test lamp while cranking the engine and compare with the following:
    1. If the test lamp does not flash, check the power feed and ground circuits between the PCM and the injector connector. Refer to the wiring diagrams in Chassis Electrical for wire colors. If the circuits are faulty, repair them. If the circuits are OK, test the engine control system should be tested.
    2.  
    3. If the test lamp flashes, proceed with the testing.
    4.  

  2.  
  3. Check for fuel delivery at the suspect injector by removing the injector from the fuel rail and check for fuel and/or restrictions in the rail or injector fuel inlet. Compare your results with the following:
    1. If there is no fuel present at the injector, replace the plugged injector, or clean the restricted passage, as necessary.
    2.  
    3. If there is fuel present at the injector, proceed with the testing.
    4.  

  4.  
  5. With the injector removed from the fuel rail, connect a 12 volt source to one terminal on the injector connector and a ground wire to the other terminal. The injector should click each time the ground wire is connected and disconnected to and from the terminal.
  6.  
  7. If the injector clicks, it is OK. If it does not click it must be replaced.
  8.  

 
label.common.footer.alt.autozoneLogo