Service Procedure

Figure 1:

1. Remove the air cleaner assembly.

2. Perform fuel system pressure release as follows:

a. Loosen gas cap to release tank pressure.

b. Disconnect injector wiring harness at location shown in Figure 1.
c. Ground one terminal of the throttle body side connector.

d. Connect a jumper wire to second terminal and touch the battery positive post for no longer than ten seconds. This releases the system pressure.

e. Remove the jumper wires but leave the harness disconnected.

3. Remove the # 25 Torx screw holding down the injector cap.

Figure 2:

4. With two small screwdrivers, lift the cap off the injector using the slots provided (Figure 2).

Figure 3:

5. Note the color of the fuel injector. If the injector is red it does not need to be replaced. If the injector is black, replace it as follows:

a. Using a screwdriver placed in the hole in the rear of the electrical connector, gently pry the injector from the pod (Figure 3).
b. Make sure the injector lower 0-ring has been removed from the pod.

c. Clean the throttle body fuel injector pod with MOPAR Brake and Carburetor Parts Cleaner, PN 4318037, or equivalent.

d. From the parts package, place a new lower 0-ring on the supplied injector and a new O-ring on the injector cap. The injector will have the upper 0-ring already installed.

e. Lubricate the new 0-rings with a thin film of clean motor oil. It is important to lubricate only the 0-rings.

NOTE: Failure to do this step may result in fuel leaking past the 0- rings.

Figure 4:

f. Place the injector in the pod. Position the injector so that the cap can be installed without interference (Figure 4).
6. Reinstall the cap and push down on it to ensure a good seal.

Note: If the injector is not being replaced, the 0-ring on the cap may be reused.

7. Install the Torx screw and torque to 40 inch pounds.

8. Reconnect the injector wiring harness and tighten the gas cap.

9. Test for leaks using the DRBII. ATM test 02 activates the fuel pump and pressurizes the system. Check to insure that there is no fuel leakage from the injector.

10. Reinstall the air cleaner assembly.