Replacing Fuel Injectors In Chrysler: Step-By-Step Guide

If you're looking to replace the fuel injectors in your Chrysler Town and Country, it's important to know what you're getting into. While it may be tempting to do it yourself, this is not a DIY job and should be left to a professional. The risk of fire is reason enough, but this repair can also get complicated. Removing the injectors, intake manifold, fuel rail, and other components requires a good amount of knowledge, and if done incorrectly, it can further damage your vehicle.

The cost of replacing your fuel injectors will depend on your location and the year of your vehicle. On average, the cost is around $442, with $302 for parts and $140 for labor. You can expect prices to vary, with some shops charging as low as $296 and others as high as $4555.

There are a few symptoms that can indicate your fuel injectors need replacing. These include a rough idle, loss of power, misfiring, an odor of raw gas or visible leaks, and the check engine light coming on. If you're experiencing any of these issues, it's best to get your vehicle checked out by a certified mechanic.

When replacing your fuel injectors, it's recommended to use high-quality, OEM parts. This will ensure even power across your engine and a proper air-fuel mixture for all cylinders, resulting in smooth running. It's also important to note that fuel injector problems can lead to decreased fuel efficiency and, in some cases, make it unsafe to drive your vehicle.

If you're experiencing issues with your Chrysler Town and Country's fuel injectors, it's best to get them addressed as soon as possible to prevent further damage and keep your vehicle running smoothly.

Disconnecting the fuel lines, electrical connectors, and mounting bolts

Disconnecting the Fuel Lines:

• Before beginning, ensure the engine is cold to avoid any risk of fuel leakage or burns.
• Relieve the pressure within the fuel rail by briefly running the engine with the fuel pump fuse removed.
• Remove the upper plenum on the intake manifold, along with any cables, hoses, or wiring that may restrict access to the fuel rail and injectors.
• Carefully disconnect the supply and return fuel lines from the fuel rail. This will involve detaching the lines from the fuel rail and sealing or capping the lines to prevent fuel leakage.

Disconnecting the Electrical Connectors:

• To remove the fuel injectors, you will need to disconnect the electrical connectors that supply power to them. These connectors are usually locked in place to prevent accidental disconnection.
• Locate the locking mechanism on the electrical connector. It is often a small tab or clip that needs to be depressed or slid to one side to release the connector.
• Using a suitable tool, such as a small flat-head screwdriver, carefully release the locking mechanism. Be gentle to avoid damaging the connector or its locking tab.
• Once released, gently pull on the connector to detach it from the fuel injector.

Removing Mounting Bolts:

• With the fuel lines and electrical connectors disconnected, you can now remove the mounting bolts that secure the fuel rail in place.
• Identify the bolts that hold the fuel rail to the intake manifold. There are usually two or more bolts on each side of the rail.
• Using the appropriate size socket or wrench, loosen and remove these mounting bolts.
• With the bolts removed, carefully lift and remove the fuel rail, taking care not to damage the fuel injectors or any surrounding components.

At this point, you should have successfully disconnected the fuel lines, electrical connectors, and removed the mounting bolts securing the fuel rail. You can now proceed with the next steps in the fuel injector replacement process, such as removing and replacing the fuel injectors themselves. Remember to work carefully and refer to a qualified mechanic or repair manual if you are unsure about any steps.

Removing the upper intake manifold

To remove the upper intake manifold, follow these steps:

First, relieve the pressure within the fuel rail by briefly running the engine with the fuel pump fuse removed. This will depressurise the fuel system.

Next, remove the upper plenum on the intake manifold, along with any cables, hoses, or wiring that may be restricting access. Disconnect the throttle cable and remove all vacuum hoses to the throttle body and the upper intake. Disconnect all wire connectors to the IAC, TPS, and air temperature sensor.

Now, unbolt the upper intake mounting bolts and remove the bracket at the rear of the upper intake manifold. Disconnect the ground strap.

Finally, you can remove the upper intake manifold assembly.

Note: It is important to take precautions and disconnect the battery when working with fuel to avoid the risk of fire.

Disconnecting the injector's electrical connector

Disconnecting the fuel injector's electrical connector is a crucial step in replacing the fuel injector on your Chrysler Town and Country. Here is a detailed, step-by-step guide on how to do this:

Step 1: Before beginning any work on your vehicle, it is essential to ensure your safety. Put on safety goggles and gloves to protect your eyes and hands from any debris or fluids.

Step 2: Locate the fuel injector you need to replace. The fuel injectors will be connected to the fuel rail, which is usually located on the top of the engine.

Step 3: Relieve the pressure in the fuel system by briefly running the engine with the fuel pump fuse removed. This is an important safety precaution to prevent any accidental fuel spray or leakage.

Step 4: Disconnect the battery to prevent any accidental electrical shorts during the repair process.

Step 5: Remove the upper plenum on the intake manifold, along with any cables, hoses, or wiring that may restrict access to the fuel injector and fuel rail. This will give you better access to the fuel injector and its electrical connector.

Step 6: Identify the electrical connector for the fuel injector. It will be plugged into the fuel injector and may have a locking mechanism or a clip to secure it in place.

Step 7: Carefully release the locking mechanism or clip that secures the electrical connector. You may need to use a small screwdriver or similar tool to gently pry or release the locking mechanism. Be careful not to damage the connector or any surrounding components.

Step 8: Once the locking mechanism or clip is released, gently pull the electrical connector away from the fuel injector. You may need to wiggle it slightly to fully disconnect it.

Step 9: Place the electrical connector in a safe location away from the work area to prevent accidental damage.

Step 10: At this point, you should have access to the fuel injector and can proceed with the removal process as per the instructions in your repair manual or other relevant sources. Remember to refer to a qualified mechanic or a professional repair guide for further instructions on replacing the fuel injector.

Safety is paramount when working on your vehicle, especially when dealing with electrical systems and fuel components. Always exercise caution and refer to a professional if you are unsure about any steps in the process.

Removing the injector retaining clips

To remove the injector retaining clips, you will need to first relieve the pressure within the fuel rail by briefly running the engine with the fuel pump fuse removed. Next, remove the upper plenum on the intake manifold, along with any cables, hoses, or wiring that may be restricting access. Then, disconnect the supply and return lines from the fuel rail, and unlock and remove the electrical connectors to each fuel injector. Now, you can unbolt and remove the fuel rail from the intake manifold.

At this point, you will be able to access the injector retaining clips. To remove them, gently pry upwards on the red plunger with your fingernail or a pick device. Pull up on the red plunger until it comes up about 3/8 inch. Once it is up, squeeze the connector underneath the left area of the clip to release the electrical plug from the injector.

It is important to note that the red plunger may be difficult to pull up, and you may need to use some force. If the red lock snaps off during this process, do not worry. As long as the connector still slides on and clicks into place, your fuel injector will function properly.

Re-inserting the injector and re-assembling the engine

Once you have removed the injector that needs replacing, you can begin the process of re-insertion and reassembly.

Firstly, you will need to grease all injector seals with grease. This will ensure they go in easily. Then, you can re-insert the injector into the fuel rail, using engine oil on the O-ring to prevent any damage. The O-rings in this application fit very tightly to prevent fuel leaks, so be sure to take your time and be careful during this step.

Next, you can re-install the fuel rail. Re-connect the supply and return lines to the fuel rail, and then re-attach the electrical connectors to each fuel injector. Now, you can bolt the fuel rail back into the intake manifold.

After this, you will need to re-attach any cables, hoses, or wiring that you removed to access the fuel injectors. This may include the throttle cable, and the upper intake manifold. You will also need to re-attach the bracket at the rear of the upper intake manifold, and the ground strap.

Finally, you can run the engine and check carefully for any leaks. Once you are satisfied that there are no leaks, you can take the vehicle for a road test.

Frequently asked questions