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Rail, Fuel: Removal: Removal

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. Disconnect the negative battery cable.
  2. Center and lock the steering wheel.
  3. Remove the four nuts and the engine cover.
  4. Disconnect the fuel pressure sensor (1) harness connector.
  5. Disconnect the fuel pressure solenoid (3) harness connector.
    Fig 2: 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.

  6. Disconnect fuel tube fittings (4) and (6) and remove four fuel tubes (5) and install a protective caps on the fuel injector and fuel rail. Note and mark position of each fuel tube while removing.
  7. Disconnect the Charge Air Cooler (CAC) outlet hose from the EGR air flow control valve.
  8. Disconnect the EGR air flow control valve harness connector.
  9. Remove the air cleaner body. Refer to BODY, AIR CLEANER, REMOVAL .
  10. Partially remove the serpentine belt.
  11. Remove the generator. Refer to GENERATOR, REMOVAL .
  12. Remove the lower intermediate shaft-to-upper intermediate shaft pinch bolt and disconnect the intermediate shaft.
  13. Remove the A/C compressor and position aside.
    Fig 3: Lower Bypass Hose, EGR Cooler Supply Line & Temperature Sensor
    GC0145356Courtesy of CHRYSLER GROUP, LLC
  14. Remove the thermostat housing. Refer to THERMOSTAT, REMOVAL .
  15. Remove the water inlet elbow. Refer to TUBE, WATER INLET, REMOVAL .
  16. Disconnect the fuel quantity solenoid harness connector.
    Fig 4: Fuel Return & Fuel Rail
    GC0145392Courtesy of CHRYSLER GROUP, LLC
  17. Disconnect the fuel return (2) line from fuel rail (1).
    Fig 5: Fuel Rail & Fuel Injector Components
    GC0138999Courtesy of CHRYSLER GROUP, LLC
  18. Remove the fuel line clamp bolt (10).
  19. Disconnect rail-to-injection pump high-pressure fuel tube fittings (8) and (11). Remove and discard fuel tube (9).
    Fig 6: High Pressure Fuel Line
    GC0145380Courtesy of CHRYSLER GROUP, LLC
  20. Remove three nuts (4) and the fuel rail.
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