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