How to Replace the Fuel Injector in a 2001 Dodge

Fuel injectors are attached to a fuel injector manifold -- a pipe that carries the fuel to the injectors. To remove one fuel injector, you must remove all fuel injectors, since they are all attached to the fuel rail. You should also replace the gaskets -- not just the injector you are replacing -- to ensure that there are no fuel leaks. Fuel injectors seldom malfunction, but they do get dirty, which causes them not to work properly. If the noid light test shows the injector is bad, you must replace the injector.

Things You'll Need

• Needle nose pliers
• Set of wrenches
• Screwdriver
• Tape and marker
• Set of line wrenches
• Set of sockets
• Torque wrench (inch-pounds)

Instructions

1. Locate the relay box near the driver's side fenderwell. Lift the cover off the box, and using the diagram, locate the fuel pump relay. Pull the relay out with your fingers. If your fingers aren't strong enough, you can use the needle nose pliers to extract the relay. Start the Dodge and let it run until it runs out of fuel.

2. Disconnect the negative battery cable, using the appropriate wrench, and set it aside, ensuring that it does not touch metal. Remove the air inlet resonator, using the screwdriver. Unhook the accelerator and cruise control cables, using your fingers or a screwdriver.

3. Unplug the idle air control valve connector, throttle position sensor connector and the engine coolant temperature connector. Label all vacuum lines on the upper intake manifold, using the tape and marker. Remove the lines from the upper intake, using the screwdriver to loosen the clamps, then pulling the lines off their connections.

4. Remove the fuel line, using the appropriate line wrench. Remove the ignition coil, using the appropriate socket. Remove the PCV hose and brake booster vacuum line, using the screwdriver.

5. Remove the upper intake manifold, using the appropriate socket. Unplug the fuel injector harness connectors. Lift the fuel supply manifold, with the injectors attached. Loosen the retaining clip on the bad injector, then pull the bad injector off the fuel rail.

6. Install the new fuel injector onto the rail and reattach the clip. Remove the O-rings from all fuel injectors and install new O-rings. If the O-rings are difficult to slide on, lubricate them with gas.

7. Line up the injector manifold and injectors on the intake. Evenly lower the injectors into the manifold. Evenly press the assembly into place, ensuring that all the injectors snap into place. Tighten the injector manifold bolts to 115 inch-pounds of torque.

8. Plug in the fuel injector wiring harness connectors, ensuring that they snap into place. Reinstall the upper intake manifold, using a new gasket. Tighten the bolts to 115 inch-pounds of torque, starting with the third bolt back on the passenger side, then working your way around the intake to the third bolt back on the driver's side, second bolt back on the driver's side, second bolt back on the passenger side, last bolt on the passenger side, last bolt on the driver's side, first bolt on the driver's side, and first bolt on the passenger side.

9. Reinstall the ignition coil and fuel line. Reattach the upper intake manifold vacuum lines, the PCV and the brake booster vacuum line. Plug in the ECT sensor, throttle position sensor and the IAC valve connectors. Reattach the accelerator and cruise control cables. Reinstall the air inlet resonator. Reattach the negative battery cable. Reinstall the fuel pump relay.

Resources

• Auto Zone: Repair Manual for 2001 Dodge: Fuel Injectors
• Auto Zone: Repair Manual for 2001 Dodge: Upper Intake Manifold