Lines-High Pressure: Installation

Fig 1: FUEL LINE SEALING CONE

Courtesy of DAIMLERCHRYSLER CORP.

1 - FUEL RAIL

2 - HIGH PRESSURE FUEL LINES

3 - HIGH PRESSURE LINE SEALING CONE

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 1600 bar (23,200 psi). Use extreme caution when inspecting for high-pressure fuel leaks. Fuel under this amount of pressure can penetrate skin causing personal injury or death. Inspect for high-pressure leaks with a sheet of card board. Wear safety goggles and adequate protective clothing when servicing fuel system.

WARNING: No sparks, open flames or smoking. Risk of poisoning from inhaling and swallowing fuel. Risk of injury to eyes and skin from contact with fuel. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing.

Loosen the fuel rail mounting bolts to install lines free of stress.
CAUTION: Inspect sealing cone at lines. See Fig 1. Replace if compression points exist. Ensure lines are exactly located.
Position and install fuel lines. Tighten to 22 N.m (195 lbs. in.).
Tighten fuel rail to 14 N.m (124 lbs. in.).
Install engine cover.
Connect negative battery cable.
Start engine, allow to warm, turn engine off and inspect for leaks.