How to Replace a Fuel Injector in a Plymouth Voyager

The Plymouth Voyager mixes fuel and air under pressure with a fuel injector. This function was previously performed passively by carburetors until the late 1980s. One advantage of fuel injectors is the programmable firmware that allows the fuel injector to handle different fuels. A fuel injector is comprised of only the nozzle and valve; it still requires the pump to pressurize the fuel.

Instructions

1

Determine which fuel injector your Plymouth Voyager will need. This depends not only on the make and model, but also the engine size. Models built from 1991 to 1995 came with a 2.5L K, 3.0L Mitsubishi 6G72, 3.3L EGA or 3.8L EGH engine. Models made after 1995 may have a 2.4L EDZ, 3.0L Mitsubishi 6G72, 3.3L EGA or 3.8L EGH engine.

2

Release the fuel system pressure and disconnect the negative battery cable with a socket wrench. Remove the air inlet resonator, accelerator cable and cruise control cable, if present. Unplug the connectors for the idle air control valve, throttle position sensor and engine coolant temperature sensor.

3

Remove the vacuum hoses, fuel lines and ignition coil for the upper intake manifold with a socket wrench. This will allow you to disconnect the upper intake manifold. Unplug the fuel injector electrical harness and remove the retaining bolts for the fuel supply manifold with a socket wrench. Lift out the fuel supply manifold with the injectors still attached.

4

Release the retainer clips for the injectors and remove the injectors from the fuel supply manifold. Discard the O-ring seals.

5

Install the new fuel injectors by reversing the removal procedure. Use a torque wrench to tighten the retaining bolts for the fuel supply manifold to 115 inch pounds.