Hey -

So I overtightened the oil filter cap on my 2018 pacifica hybrid the other day and, now I know, that's bad, and anyway I just finished replacing the cooler and it went mostly like the video below (except with more crap in the way because it's a hybrid) and also went ahead and changed the spark plugs and pcv valve while I was in there. Got everything back together and it starts and runs great and as far as I can tell the cooler is no longer leaking and is working as intended.





Where it has gone wrong is that it is dripping fuel out the underside like crazy -I had to take off the fuel rail on my way down to the cooler and I also swapped out o-rings on the fuel injectors since they were looking stiff and flat so my guess is it's related.

I got back down to that layer of my engine and everything *looked* to be in place correctly - injectors lined up properly in their holes and in the rail. The best I could tell is that maybe the leak was coming from the back set of cylinders - at least it looked wet back there before I removed the rails and fuel dripped out but it's hard to say you really can't see much with the rails one. One containment tooth for the rear middle injector did fall off the fuel rail when I removed it again like it had snapped on reassembly.

Any ideas? I am hoping I don't need to shell out for a new fuel rail because of that broken tab- that would suck (would still be in this entire repair for less than the cost of someone else fixing the oil cooler though).


ETA:

Maybe one of the injectors wasn't really lined up properly, causing the tab to snap when tightened and also there to be enough looseness for fuel to escape? Any other possibilities? I would also really hate to put this thing back together again and still have it be leaking.

I've seen the o-rings on injectors roll. They usually require a bit of a tap when going in also.

Did you lube up the o rings before you inserted them?

Goin' in dry makes them die.

Good point, I did not, will any lubricating oil work for that?

I have a little can of quite soft grease made specifically for O ring use. A guy that own a hydraulic assembly  repair shop nearby gave it to me. He said almost all new o ring failures are due to lack of lubrication when assembling. I would imagine it's a silicone based grease, very soft, almost slimy it's so slick.

Oh, it sucked bad. I am pissed off that some bean counter at Chrysler wanted to save a few bucks instead of using an aluminum unit. All the aftermarket units are aluminum, I should never have the problem again.

I also wanted to replace the coolant since it is getting older and undoubtedly got some oil in it from the cooler going bad and changing it out but there is no way to do that, no drain or anything. The only way would have been to pull a 2" diameter hose down at the bottom but I couldn't get it to budge after I got the clamp moved.

I lubed and re-set all the O-rings and was extremely careful with injector alignment with the fuel rails and no leaks this time around. I think an injector on the back must have been out of alignment as one of its tabs was snapped off.

Thanks for the suggestions.

Agree with putting lube on the injector orings but don’t use anything with silicone. It’ll likely kill the O2 sensors.

This topic has been discussed at considerable length at one of the Pacifica forums.  Specifically, pacificaforums.com
A couple of example threads:  https://www.pacificaforums.com/threads/dealer-damaged-nut-on-top-of-oil-filter-canister.49608/#post-621067
https://www.pacificaforums.com/threads/2017-oil-filter-housing-replacement-notes-and-cross-reference.51351/#post-641546

That forum in particular isn't quite as technical as I would like it to be.  But it's getting better.