SOLENOID, Fuel Pressure: Installation: Installation

NOTE: Review the high pressure fuel system warning before beginning repair. See Fuel System - Standard Procedure .

Fig 1: FUEL RAIL PRESSURE SOLENOID

Courtesy of CHRYSLER LLC

WARNING: Before working on an open fuel system, eliminate any source of sparks or open flames near the work area, and do not smoke. Wash diesel fuel off skin as soon as possible to avoid the risk of poisoning from inhaling and swallowing fuel. Do not allow diesel fuel to come in contact with eyes, otherwise, severe injury can result from contact with fuel. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing whenever possible to avoid injury.

CAUTION: There is a special tightening procedure for the fuel rail solenoid that must be followed along with the proper use of a torque wrench. Therefore the fuel rail must be removed before installing the fuel pressure solenoid.

CAUTION: Do not reuse an existing fuel pressure solenoid. A new fuel pressure solenoid must be installed any time the existing solenoid has been removed from the fuel rail.

1. Position the fuel rail (2) into a soft jawed vise.
2. Inspect the sealing surfaces of the fuel pressure solenoid opening in the fuel rail. If any cuts or gouges are present in the fuel rail pressure solenoid opening, replace the fuel rail.
3. Lubricate the fuel pressure solenoid sealing rings with clean diesel fuel. Do not allow dirt or debris to come in contact with the fuel rail solenoid or the threads in the fuel rail.
4. Manually thread the fuel pressure solenoid (3) into the fuel rail until hand tight.
5. Position the fuel pressure solenoid electrical socket so the fuel pressure solenoid harness connector is not under stress. Otherwise, the connector or harness can be damaged.
6. Counterhold the fuel rail, and tighten the fuel rail solenoid (3) as follows:
   1. Tighten the fuel pressure solenoid to 60 N.m (44 ft. lbs.)
   2. Loosen the fuel pressure solenoid 90 degrees.
   3. Retighten the fuel pressure solenoid to 85 N.m (62 ft. lbs.).
7. Install fuel rail. See Fuel System/Fuel Injection/INJECTOR(S), Fuel - Installation .
8. Connect negative battery cable.
9. Start engine, allow to warm, turn engine off and inspect for leaks.