Dodge Nitro. Manual — part 665

1. Refer to WARNING. Run engine until operating temperature is obtained.

2. Turn Off the ignition.

3. Disconnect the fuel injector fuel return hose (3) at the return hose tee directly behind the generator, next

to the air purge fitting, leaving the return hose to the high pressure injection pump connected to the pump
(1).

Fig. 39: Diesel Fuel System Components
Courtesy of CHRYSLER LLC

4. Block off fuel return line (3) to high pressure injection pump.

5. Connect a hose to the return hose tee and place it in a suitable container.

6. Start the engine and use a suitable measuring cup to measure the return fuel flow for 1 minute at idle.

NOTE:

The fuel pump pressure must be between 0.8 and 1.2 bar (13-17 psi), and engine
must be at operating temperature, engine coolant 88°C (190°F).

1 - HIGH PRESSURE FUEL INJECTION PUMP
2 - FUEL PRESSURE SOLENOID
3 - AIR PURGE FITTING
4 - FUEL INJECTOR FUEL RETURN HOSE TEE
5 - HIGH PRESSURE FUEL SUPPLY LINE
6 - FUEL INJECTOR
7 - FUEL RAIL
8 - FUEL RAIL PRESSURE SENSOR
9 - FUEL RAIL RETURN LINE

NOTE:

If the quantity of fuel is above 100ml. it means one or more of the fuel

2007 Dodge Nitro R/T

2007 ENGINE Fuel System - Nitro

7. If the measured return fuel flow quantity is above 100ml, disconnect each individual injector and measure

the quantity of return fuel into the container.

8. Replace any fuel injector that has a return rate above 25ml. for one minute at idle. See REMOVAL.

9. If the test does not give a positive result, disconnect the fuel return line at the fuel rail. If fuel is present,

replace the fuel rail. See REMOVAL.

10. Perform the fuel system air purge procedure after replacing any components. See STANDARD

PROCEDURE.

HIGH PRESSURE LEAKS

Fig. 40: Typical Test For Fuel Leak
Courtesy of CHRYSLER LLC

injectors has a problem.

NOTE:

Make sure to block off the fuel return hose at each individual fuel injector
before taking a measurement.

1 - HIGH-PRESSURE LINE
2 - CARDBOARD
3 - FITTING

WARNING:

High-pressure lines deliver diesel fuel under extreme pressure from the
injection pump to the fuel injectors. This may be as high as 160,000 kpa
(23,206 psi). Use extreme caution when inspecting for high-pressure fuel
leaks. Fuel under this amount of pressure can penetrate skin causing
personal injury or death. Inspect for high-pressure fuel leaks with a sheet

2007 Dodge Nitro R/T

2007 ENGINE Fuel System - Nitro

High-pressure fuel leaks can cause starting problems and poor engine performance.

Carefully place a piece of cardboard (2) over the high-pressure fuel lines or suspected area. Move your body
and hands away from the area. Start the engine and run till warm. TURN THE ENGINE OFF . Inspect the
piece of cardboard for witness marks. If a high-pressure line connection is leaking, replace damaged, restricted
or leaking high-pressure fuel lines with the correct replacement line.

STANDARD PROCEDURE

STANDARD PROCEDURE - DRAINING FUEL TANK

Fig. 41: Identifying Fuel Fill Hose, Fuel Fill Hose Clamp & Tank
Courtesy of CHRYSLER LLC

1. Disconnect negative battery cable.

2. Remove fuel fill cap.

3. Raise and support vehicle.

4. Remove fuel fill hose clamp (2) at rear of tank (3).

5. Remove fuel fill hose (1) from fuel tank.

6. Position a drain hose into the fuel fill hose opening. Note that a small flapper valve is installed into the

opening.

7. Drain fuel tank using an approved gasoline, or diesel fuel draining station.

of cardboard. Wear safety goggles and adequate protective clothing when
servicing fuel system.

CAUTION: The high-pressure fuel lines cannot contact each other or other

components. Do not attempt to weld high-pressure fuel lines or to repair
lines that are damaged. Only use the recommended lines when
replacement of high-pressure fuel line is necessary.

2007 Dodge Nitro R/T

2007 ENGINE Fuel System - Nitro

CLEANING FUEL SYSTEM COMPONENTS

SPECIFICATIONS

TORQUE SPECIFICATIONS-2.8L DIESEL

TORQUE SPECIFICATIONS

CAUTION: Cleanliness cannot be overemphasized when handling or replacing diesel

fuel system components. This especially includes the fuel injectors, high-
pressure fuel lines, fuel rail, and fuel injection pump. Very tight tolerances
are used with these parts. Dirt contamination could cause rapid part wear
and possible plugging of fuel injector nozzle tip holes. This in turn could
lead to possible engine misfire. Always wash/clean any fuel system
component thoroughly before disassembly and then air dry. DO NOT wire
brush injector nozzles when cleaning. Cap or cover any open part after
disassembly. Before assembly, examine each part for dirt, grease or other
contaminants and clean if necessary. When installing new parts, lubricate
them with clean engine oil or clean diesel fuel only.

DESCRIPTION

N.m

Ft. Lbs.

In. Lbs.

Fuel Filter Housing

Bleeder Screw

10

-

89

Crankshaft Position

Sensor Bolt

11

-

97

Crankshaft Position

Sensor Shield Bolt

11.8

-

104

Boost Pressure/Intake Air

Temperature Sensor Bolts

11.8

-

104

Return Fuel Junction

Block at Intake Manifold

10.8

-

96

Fuel Filter

18

-

159

Fuel Filter Screw to

Housing

30

22

-

High Pressure Injection

Pump Nuts

24.5

18

-

Fuel Line Fittings at

Pump

24

17

-

Fuel Rail Sensor

35

25

-

Fuel Line Fittings at

Filter Housing

35

25

-

High Pressure Injection

Pump Sprocket Nut

88.3

65

-

Fuel Injector Retaining

Bolts

32.4

24

-

High Pressure Fuel Lines

2007 Dodge Nitro R/T

2007 ENGINE Fuel System - Nitro