Dodge Nitro. Manual — part 671

Fig. 61: Fuel Injectors - 2.8L Diesel
Courtesy of CHRYSLER LLC

3. Install the injectors (8), the injector clamps (7) and washers (6).

4. Install the injector bolts (5). Do not tighten at this time.

5. Position and connect the high pressure line (12) between the high pressure injection pump and the fuel

rail. Do not tighten at this time.

6. Torque injector clamp bolts to 32.4 Nm (23 ft. lbs.).

7. Torque the rail side (4) of the high pressure lines between the injectors and the fuel rail to 5 Nm (44 in.

lbs.) plus an additional 75°.

8. Torque the injector side (2) of the high pressure lines between the injectors and the fuel rail to 28 Nm (20

ft. lbs.).

9. Torque the rail side (9) of the high pressure fuel line between the high pressure injection pump and the

fuel rail to 5 Nm (44 in. lbs.) plus an additional 75°.

10. Torque the high pressure pump side (11) of the high pressure fuel line between the high pressure injection

pump and the fuel rail to 28 Nm (20 ft. lbs.).

11. Install fuel line clamp bolt (10). Tighten bolt to 15 N.m (11 ft. lbs.) torque.

CAUTION: WHEN LOOSENING OR TIGHTENING HIGH-PRESSURE LINE

FITTINGS ATTACHED TO A SEPARATE FITTING, USE A BACK-UP
WRENCH ON FITTING. DO NOT ALLOW FITTING TO ROTATE.
DAMAGE TO BOTH FUEL LINE AND FITTING WILL RESULT.

2007 Dodge Nitro R/T

2007 ENGINE Fuel System - Nitro

Fig. 62: Exploded View Of Fuel Rail - 2.8L Diesel
Courtesy of CHRYSLER LLC

12. Connect electrical connectors to fuel injectors.

13. Connect electrical connector to fuel pressure solenoid (3).

14. Connect electrical connector to fuel pressure sensor (1).

15. Install the engine cover.

16. Connect negative battery cable to battery.

LINES-FUEL

DESCRIPTION

DESCRIPTION

Low-Pressure Lines Are:

The fuel supply line from fuel tank to fuel filter housing.

The fuel return line back to fuel tank.

The fuel drain line from each fuel injector.

The fuel supply line from fuel filter to fuel injection pump.

The fuel injection pump return line.

High-Pressure Lines Are:

2007 Dodge Nitro R/T

2007 ENGINE Fuel System - Nitro

The fuel line from fuel injection pump to fuel rail.

The four fuel lines from fuel rail up to the fuel injectors

OPERATION

HIGH-PRESSURE FUEL LINES

High-Pressure Lines

High-pressure fuel lines deliver fuel (under pressure) of up to approximately 160,000 kpa (23,206 psi) from the
injection pump to the fuel injectors. The lines expand and contract from the high-pressure fuel pulses generated
during the injection process. All high-pressure fuel lines are of the same length and inside diameter. Correct
high-pressure fuel line usage and installation is critical to smooth engine operation.

DIAGNOSIS AND TESTING

HIGH-PRESSURE FUEL LINE LEAK TEST

WARNING:

High-pressure fuel 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. Inspect for high-pressure fuel leaks with a sheet of cardboard.
High fuel injection pressure can cause personal injury if contact is made
with the skin.

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. If lines are ever kinked or bent, they must be
replaced. Use only the recommended lines when replacement of high-
pressure fuel line is necessary.

WARNING:

Use extreme caution when inspecting for high-pressure fuel leaks.
Inspect for high-pressure fuel leaks with a sheet of cardboard. High fuel
injection pressure can cause personal injury if contact is made with the
skin.

2007 Dodge Nitro R/T

2007 ENGINE Fuel System - Nitro

Fig. 63: High-Pressure Fuel Line Leak Test
Courtesy of CHRYSLER LLC

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

Start the engine. Move the cardboard (2) over the suspected high-pressure fuel line leak, and check for fuel
spray onto the cardboard. If line is leaking, retorque line while engine is shutdown. Replace damaged, restricted
or leaking high-pressure fuel lines with the correct replacement line.

REMOVAL

HIGH-PRESSURE FUEL LINES

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

WARNING:

Due to extreme fuel pressures of up to 160,000 kpa (23,207 psi), use
extreme caution when inspecting for high-pressure fuel leaks. Do not get
your hand or a finger near a suspected leak. Inspect for high-pressure
fuel leaks with a sheet of cardboard (2) (typical picture). High fuel
injection pressure can cause personal injury if contact is made with the
skin.

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