Dodge Nitro. Manual — part 675

FUEL PRESSURE SENSOR

Review the high pressure fuel system warning. See WARNING.

The fuel flows to the fuel pressure sensor through an opening in the rail, the end of which is sealed off by the
sensor diaphragm. Pressurized fuel reaches the sensor's diaphragm through a blind hole. The sensor element
(semiconductor device) converts the pressure to an electric signal is mounted on this diaphragm. The signal
generated by the sensor is monitored by the ECM.

REMOVAL

FUEL PRESSURE SENSOR

1. Disconnect negative battery cable.

2. Remove engine cover.

3. Clean the area around the fuel pressure sensor with Mopar® Throttle Body Cleaner P/N 04897156AA or

equivalent degreasing solvent and compressed air.

4. Disconnect fuel pressure sensor electrical connector.

WARNING:

High pressure fuel spray can cause severe cuts, and is extremely
flammable. Before opening any part of the high pressure fuel
system, wait for a minimum of 30 seconds after turning off the
engine to allow pressure to bleed down from the high pressure side
of the fuel system. Otherwise severe personal injury can result when
the high pressure fuel system is opened.

WARNING:

No sparks, open flames or smoking. Risk of poisoning from inhaling
and swallowing fuel. Risk of injury to eyes and skin from contact
with fuel. Pour fuels only into suitable and appropriately marked
containers. Wear protective clothing.

NOTE:

Do allow cleaning solvent or debris to enter the fuel pressure sensor
harness connector.

WARNING:

When working with parts on the high side of the fuel injection
system such as the fuel rail and high pressure injector lines, slowly
loosen the part to allow any residual pressure to bleed down from
the high pressure side of the system.

2007 Dodge Nitro R/T

2007 ENGINE Fuel System - Nitro

Fig. 78: Exploded View Of Fuel Rail - 2.8L Diesel
Courtesy of CHRYSLER LLC

5. Remove fuel pressure sensor (1) from fuel rail.

6. If the sensor is to be reused, remove the fuel rail pressure sensor sealing ring. Do not damage or gouge the

fuel rail pressure sensor threads. If any gouges or cuts are present in the fuel rail pressure sensor threads,
the sensor must be replaced. Otherwise, fuel leaks can occur.

7. Clean the thread and fuel pressure sensor sealing surface of the fuel rail.

8. Use a clean plug to close off the fuel rail pressure sensor opening if the fuel pressure solenoid will not be

immediately re-installed.

INSTALLATION

FUEL PRESSURE SENSOR

NOTE:

Do not touch the connector terminals of the fuel rail pressure sensor. The
internal electronic components of the sensor can be damaged.

NOTE:

Do not allow dirt or debris to enter the fuel rail and fuel rail solenoid
threads after the fuel pressure solenoid has been removed from the fuel
rail.

WARNING:

Diesel fuel is under extreme pressure in the high pressure side of the fuel

2007 Dodge Nitro R/T

2007 ENGINE Fuel System - Nitro

Fig. 79: Exploded View Of Fuel Rail - 2.8L Diesel
Courtesy of CHRYSLER LLC

1. If reusing an existing fuel pressure sensor, install a new fuel pressure sensor sealing ring.

2. Lubricate the fuel pressure sensor threads and sealing ring with clean diesel fuel.

3. Install fuel pressure sensor (1) in fuel rail (2). Position the fuel rail pressure sensor so the harness

connector is not stretched or under tension. Tighten sensor to 100 N.m (73 ft. lbs.).

4. Connect fuel pressure sensor electrical connector.

5. Install engine cover.

6. Connect negative battery cable.

SOLENOID-FUEL PRESSURE

DESCRIPTION

FUEL PRESSURE SOLENOID

injection system between the fuel injectors and the high pressure fuel
pump. This may be as high as 1600 bar (23,200 psi.). Use extreme caution
when inspecting for leaks in the high pressure side of the fuel injection
system. Fuel under this amount of pressure can penetrate skin causing
personal injury or death. Inspect for high pressure fuel leaks with a sheet
of cardboard. Wear safety goggles and adequate protective clothing when
servicing the high pressure side of the fuel system.

2007 Dodge Nitro R/T

2007 ENGINE Fuel System - Nitro

Fig. 80: Exploded View Of Fuel Rail - 2.8L Diesel
Courtesy of CHRYSLER LLC

The fuel pressure solenoid (3) is attached to the rear of the fuel rail (2). The tip of the fuel pressure solenoid (3)
uses a knife edge, for metal to metal sealing. The knife edge actually deforms the metal in the fuel rail in order
to seal the surfaces. The solenoid must be replaced when ever it is removed from the rail. The solenoid controls
and maintains constant rail pressure with a control current transmitted by the engine control module (ECM).

OPERATION

FUEL PRESSURE SOLENOID

2007 Dodge Nitro R/T

2007 ENGINE Fuel System - Nitro