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Rail, Fuel: Installation: Installation

CAUTION:

Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight tolerances are used with these components. Dirt contamination can cause rapid part wear and possibly plug fuel injector nozzle tips. This in turn could lead to possible engine misfire. Always clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open component after disassembly. Before assembly, examine each component for dirt, grease or other contaminants and clean if necessary. When installing new components, lubricate them for assembly with clean engine oil or clean diesel fuel only.

CAUTION:

Any time a high pressure fuel line has been loosened or disconnected, that high pressure fuel line must be replaced. Failure to follow these instructions may lead to a high pressure fuel leak.

Fig 1: High Pressure Fuel Line
GC0145380Courtesy of CHRYSLER GROUP, LLC
  1. Install the fuel rail (2) to the cylinder head. Tighten nuts (4) to 24 N.m (18 ft. lbs.).
  2. Disconnect the fuel pressure solenoid (3) harness connector.
  3. Disconnect the fuel pressure sensor (1) harness connector.
    Fig 2: Fuel Return & Fuel Rail
    GC0145392Courtesy of CHRYSLER GROUP, LLC
  4. Connect the fuel return line (2) onto fuel rail (1).
    Fig 3: Fuel Rail & Fuel Injector Components
    GC0138999Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    When loosening or tightening high-pressure line fittings, use a back-up wrench on each fitting. Do not allow any fitting to rotate. Damage to both fuel line and fitting will result.

  5. Install a new high pressure supply tube (9). Tighten the fittings as follows:
    • Tighten fitting (8) to 5 N.m (44 in. lbs.) plus an additional 75 degrees.
    • Tighten fitting (11) to 28 N.m (20 ft. lbs.).
  6. Install the fuel quantity solenoid. Refer to SOLENOID, FUEL QUANTITY, INSTALLATION .
  7. Install the bolt (10) that secures the fuel supply line bracket to the intake manifold. Tighten the bolt to 15 N.m (133 in. lbs.).
  8. On 4x4 models, install the front axle. Refer to INSTALLATION .
  9. Remove the protective caps and install new high pressure fuel injector tubes (5). Tighten the fittings as follows:
    • Tighten fittings (6) to 5 N.m (44 in. lbs.) plus an additional 75 degrees.
    • Tighten fittings (4) to 28 N.m (20 ft. lbs.).
  10. Install the EGR cooler.
  11. Install the battery. Refer to BATTERY, INSTALLATION .
  12. Connect the Charge Air Cooler (CAC) outlet hose to the EGR air flow control valve.
  13. Install the silencer and the four retainers.
  14. Install the engine cover.
  15. Reconnect the negative battery cable.
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