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Rail, Fuel: Installation: Installation

NOTE:

New High Pressure Fuel Line must be used any time the High Pressure Fuel Lines have been removed.

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 parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only.

Fig 1: High Pressure Fuel Line
GC0145380Courtesy of CHRYSLER GROUP, LLC
  1. Position fuel rail (2) to cylinder head.
  2. Install three fuel rail mounting nuts (4). Tighten nuts (alternately) to 24 N.m (18 ft. lbs.).
    Fig 2: Fuel Rail & Fuel Injector Components
    GC0138999Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    WHEN LOOSENING OR TIGHTENING HIGH-PRESSURE LINE FITTINGS ATTACHED TO A SEPARATE FITTING, USE A BACK-UP WRENCH ON FITTING. DO NOT ALLOW FITTING TO ROTATE. DAMAGE TO BOTH FUEL LINE AND FITTING WILL RESULT.

    NOTE:

    When ever a fuel tube connection is loosened, new fuel tubes MUST be used.

  3. Install the new fuel tube (9) and connect rail-to-injection pump high-pressure fuel line fittings (8) and (11).
  4. Tighten the high pressure fuel feed tube at the high pressure pump (11) to 28 N.m (20 ft. lbs.).
  5. Tighten the high pressure fuel feed tube at the fuel rail (8) to 5 N.m (44 in. lbs) plus an additional 75 degrees.
  6. Install fuel line clamp bolt (10). Tighten to 15 N.m (133 in. lbs.).
    Fig 3: Fuel Return & Fuel Rail
    GC0145392Courtesy of CHRYSLER GROUP, LLC
  7. Connect the fuel return (2) line from fuel rail (1).
    Fig 4: Lower Bypass Hose, EGR Cooler Supply Line & Temperature Sensor
    GC0145356Courtesy of CHRYSLER GROUP, LLC
  8. Connect the fuel quantity solenoid harness connector.
  9. Install the water inlet elbow. Refer to TUBE, WATER INLET, INSTALLATION .
  10. Install the thermostat housing. Refer to THERMOSTAT, INSTALLATION .
    Fig 5: Fuel Rail & Fuel Injector Components
    GC0138999Courtesy of CHRYSLER GROUP, LLC
  11. Install the A/C Compressor. Tighten the bolts to 28 N.m (21 ft. lbs.).
  12. Connect the upper intermediate shaft-to-lower intermediate shaft. Tighten pinch bolt to 49 N.m (36 ft. lbs.).
  13. Install the generator Refer to GENERATOR, INSTALLATION .
  14. Install the serpentine belt.
  15. Install the air cleaner body. Refer to BODY, AIR CLEANER, INSTALLATION .
  16. Connect the EGR air flow control valve harness connector.
  17. Connect the Charge Air Cooler (CAC) outlet hose from the EGR air flow control valve.
  18. Remove the protective caps from the fuel injectors and install new high pressure fuel tubes (5). Only hand tighten the high pressure fuel line (4) and (6).
  19. Tighten the high pressure fuel tube (4) on the fuel injector to 28 N.m (20 ft. lbs.).
  20. Tighten the high pressure fuel tube (6) on the fuel rail to 5 N.m (44 in. lbs) plus an additional 75 degrees.
    Fig 6: High Pressure Fuel Line
    GC0145380Courtesy of CHRYSLER GROUP, LLC
  21. Connect the fuel pressure solenoid (3) harness connector.
  22. Connect the fuel pressure sensor (1) harness connector.
  23. Install the engine cover and securely tighten the four nuts.
  24. Remove the steering wheel lock.
  25. Connect the negative battery cable.
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