Fuel Delivery - 2.2L Diesel: Rail-Fuel: Installation

WARNING: High-pressure fuel lines deliver fuel under extreme pressure from the injection pump to the injectors. This maybe 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 high-pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system.

WARNING: No fire, flames or smoking. Risk of poisoning from inhaling or 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.

Fig 1: FUEL RAIL MOUNTING BOLTS

Courtesy of DAIMLERCHRYSLER CORP.

1 - FUEL RAIL

2 - FUEL RAIL MOUNTING BOLTS

1. Position fuel rail to cylinder head. Tighten bolts finger tight only  .
2. Position and loosely install fuel return line from fuel filter, with new seals to rail (1).
3. Connect high pressure line from pump to rail at rail (1). Tighten line finger tight only. 
4. Torque fuel rail bolts (2) to 14 N.m (124 in. lbs.). See Fig 1.
5. Tighten nut of high pressure line at fuel rail to 22 N.m (194 in. lbs.).
6. Tighten banjo bolt of fuel return line to fuel rail to 20 N.m (177 in. lbs.).
   Fig 2: HIGH PRESSURE LINES AT INJECTORS - TYPICAL

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - HIGH PRESSURE LINE

   2 - CYLINDER HEAD COVER

   3 - FUEL RAIL

   CAUTION: Inspect sealing cones at the lines. Replace as necessary. Ensure that all fuel pressure lines are exactly located in original position.
7. Install high pressure lines (1) to injectors. See Fig 2. Tighten nut of pressure line to rail/injector to 22 N.m (194 in. lbs.).
8. Reconnect fuel rail pressure sensor and fuel pressure solenoid electrical connectors.
   Fig 3: Battery Location

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - BATTERY

   2 - PASSENGER SEAT

9. Connect negative battery (1) cable located under passenger seat. See Fig 3.
   Fig 4: Engine Cover Mounts

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - ENGINE COVER RETAINING NUTS

   2 - ENGINE COVER

   3 - ENGINE COVER MOUNTS

   4 - ENGINE COVER MOUNTING STUDS

   WARNING: High-pressure fuel lines deliver fuel under extreme pressure from the injection pump to the injectors. This maybe 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 high-pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system.
10. Start engine and inspect for leaks.
11. Install engine cover (2). See Fig 4.
12. Install engine cover retaining nuts (1) and tighten.