Dodge Nitro. Manual - part 688

Fig. 133: Fuel Injectors - 2.8L Diesel
Courtesy of CHRYSLER LLC 

4. Locate common fuel return line (1). 

Fig. 134: Lifting Lock Buttons 
Courtesy of CHRYSLER LLC 

5. Disconnect electrical connector at top of injector(s). 

6. A lock button (1) is used to secure the common fuel return line to each fuel injector. Use your fingers to 

lift all four lock buttons (1) up. After unlocking all four buttons, lift fuel return line assembly up for 
removal. 

NOTE:

The injector common fuel return line is connected to the low pressure fuel 
circuit (5 bar/72 psi).

 

2007 Dodge Nitro R/T 

2007 ENGINE Fuel System - Nitro

  

Fig. 135: Identifying Injector, Mounting Clamp, Mounting Bolt & Washer 
Courtesy of CHRYSLER LLC 

7. Remove injector mounting bolt (2) and washer (3).  

8. Remove injector mounting clamp (1).  

9. Using compressed air, thoroughly clean surface area in and around injector bore to prevent foreign 

material from falling into the injector bore after injector removal.  

10. Using your hand, pull fuel injector straight up from cylinder head for removal. 

Fig. 136: Installing Special Fuel Injector Removal Tool #9552 To Top Of Fuel Injector 
Courtesy of CHRYSLER LLC 

 

2007 Dodge Nitro R/T 

2007 ENGINE Fuel System - Nitro

  

11. If injector can't be removed by hand, install special fuel injector removal tool #9552 (2) to top of fuel 

injector. 

Fig. 137: Installing Special Slide Hammer Tool #8941 Onto Special Tool #9552, Tightening Lock 
Nut & Removing Injector From Cylinder Head 
Courtesy of CHRYSLER LLC 

12. Install special slide hammer tool #8941 (1) onto special tool #9552 (4). Tighten lock nut (2). Remove 

injector from cylinder head.  

INSTALLATION 

INSTALLATION 

NOTE:

DO NOT use a wire brush to clean the fuel injector or nozzle. Possible 
restriction of the injector needle may result.

CAUTION: Due to the complexity of the fuel injection system used on this engine, 

refer to the Diesel Engine Diagnostics, and service any fuel system DTCs 
prior to replacing any fuel injectors. If no DTCs are present, refer to the 
Diesel Engine Diagnostic Test for Lack of Engine Power, and perform all 
steps as directed prior to replacing any fuel injectors.

CAUTION: Cleanliness cannot be overemphasized when handling or replacing diesel 

fuel system components. This especially includes the fuel injectors, high-
pressure fuel lines 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 

 

2007 Dodge Nitro R/T 

2007 ENGINE Fuel System - Nitro

  

Fig. 138: Identifying Injector Nozzle & Copper Washer/Seal 
Courtesy of CHRYSLER LLC 

1. Install fuel injector into cylinder head with new seal. 

thoroughly before disassembly and then air dry. 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.

NOTE:

DO NOT use a brush to clean around the injector nozzle (2). DO NOT lubricate 
area around injector nozzle. The injector may become restricted with debris.

NOTE:

Be sure a new copper washer/seal (3) is installed on end of injector and the old 
seal is removed, before installing in cylinder head.

 

2007 Dodge Nitro R/T 

2007 ENGINE Fuel System - Nitro