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Home >> Chrysler >> 2008 >> Sebring Limited, 2D Convertible >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Fuel System >> Fuel Injection-Diesel >> Fuel Injector >> Installation
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Fuel Injector: Installation

NOTE: The injector clearance adjustment procedure must be performed any time an injector has been removed from the cylinder head.
CAUTION: PAY CLOSE ATTENTION TO THE FOLLOWING POINTS WHEN INSTALLING FUEL INJECTORS.
  1. Blow out injector recesses, clean again with non-woven cloth and then cover over. Fiber residues from non-woven cloth ARE NOT permissible.
  2. Carefully carry out a visual inspection of the sealing surfaces of the injector recesses.
  3. The length of the round brush can be adjusted and should be approximately 3mm for cleaning the seal seat. Optimal cleaning is achieved only if a brush with a flat surface is used. If necessary the surface of the brush can be ground flat on a grinding stone.
  4. ALWAYS replace the seals which seal off the injectors at the cylinder head to the combustion chamber. It is important that no grease gets onto the seal. Any impurities on the seal, on the sealing surfaces at the injector and cylinder head as a result of combustion residue or similar are absolutely impermissible.
  5. The screws attaching the injectors must always be replaced. The screws must screw in easily, if not, clean the threaded whole with an appropriate thread tap.
  6. The tip of the injector nozzle MUST NOT be cleaned with a wire brush. Use a non-woven cloth.
  7. Clean entire injector with a non-woven cloth.
  8. Fiber residues from a non-woven cloth are not permissible.
Fig 1: Upper Injector O-Ring
GC0055526Courtesy of CHRYSLER LLC
  1. Clean injectors and recesses. See STANDARD PROCEDURE .
  2. Coat injector (1) body with clean diesel fuel and install new upper O-ring (2) using injector O-ring protector/guide 9886 (3).
    Fig 2: Lower Injector O-Ring
    GC0055527Courtesy of CHRYSLER LLC
  3. Install new lower injector O-ring (2) using injector O-ring protector/guide 9886 (3).
    Fig 3: Seating Injectors
    GC0055528Courtesy of CHRYSLER LLC
  4. Install valve spring tool 9916 (1) on cylinder head using M-8 x 70 mm bolts (2).
    Fig 4: Injector Seating Tool
    GC0055529Courtesy of CHRYSLER LLC
  5. Position valve spring tool 9916 over injector (2).
    Fig 5: Seating Injectors
    GC0055528Courtesy of CHRYSLER LLC
  6. Seat injector by applying downward pressure on the handle of valve spring tool 9916.
    Fig 6: Fuel Injector
    GC0055530Courtesy of CHRYSLER LLC
    CAUTION: Install injector (1) using new retaining bolts.
  7. Install new injector bolts (2).
  8. Torque bolts (2) to 3 N.m (27 lbs. in.).
  9. Tighten injector retaining bolts an additional 90°.
  10. Tighten injector retaining bolts an additional 180°.
  11. Connect injector electrical connectors.
    Fig 7: Injector Shaft Torque Sequence
    GC0055531Courtesy of CHRYSLER LLC
    CAUTION: When replacing injectors, the rocker arm adjustment screws and the injector ball studs must be replaced or engine damage could result.
  12. Install injector rocker shaft.
  13. Install new rocker arm adjustment screws and the injector ball studs.
  14. Tighten injector shaft bolts to 20 N.m (15 in. lbs.) in the sequence shown.
  15. Tighten rocker arm shaft bolts an additional 90° as shown.
  16. Perform injector adjustment. See STANDARD PROCEDURE .
  17. Install cylinder head cover. Refer to INSTALLATION . Refer to INSTALLATION . Refer to INSTALLATION .
    Fig 8: Engine Cover
    GC0055532Courtesy of CHRYSLER LLC
  18. Connect negative battery cable.
  19. Start engine and check for leaks.
  20. Install engine cover. Refer to INSTALLATION . Refer to INSTALLATION . Refer to INSTALLATION .
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