Lines-High Pressure: Installation

WARNING: Observe the following precautions when working on fuel systems: No sparks, open flames or smoking. Avoid inhaling and swallowing fuel. Avoid eye and skin contact with fuel. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing. Failure to observe these precautions may result in fire, explosion, property damage, and serious or fatal injury.

WARNING: High-pressure fuel lines deliver fuel under extreme pressure from the injection pump to the injectors. This maybe as high as 1350 bar (19,580 psi). Use extreme caution when inspecting for high-pressure fuel leaks. Inspect high-pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system. Fuel under this amount of pressure can penetrate skin causing serious or fatal injury.

Fig 1: FUEL LINE SEALING CONE

Courtesy of CHRYSLER LLC

1 - FUEL RAIL

2 - HIGH PRESSURE FUEL LINES

3 - HIGH PRESSURE LINE SEALING CONE

Loosen the fuel rail mounting bolts to allow stress-free installation of high pressure fuel lines (2).
NOTE: Inspect sealing cones (3). Replace if damaged.
Position and install fuel lines (2). Tighten to 27 N.m (20 ft. lbs.).
Tighten fuel rail mounting bolts 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.