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Tube(S), Fuel: 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 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. DO NOT use any lubricating or sliding agents that contain water.

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:

All the fuel lines are of the same length and inside diameter. Correct high-pressure fuel line usage and installation is critical to smooth engine operation. When ever a fuel tube connection is loosened, a NEW  fuel tubes MUST be installed.

  1. Remove the protective caps from the fuel injectors and install the NEW  fuel tubes (5). Tighten the fuel tube fittings (4) and (6) finger tight.
  2. Tighten the fuel tube (4) on the fuel injector to 28 N.m (20 ft. lbs.).
  3. Tighten the fuel tube (6) on the fuel rail to 5 N.m (44 in. lbs) plus an additional 75 degrees.
  4. Install the NEW  fuel tube (9) and onto rail-to-fuel injection pump and tighten the fuel tube fittings (8) and (11) finger tight.
  5. Tighten the fuel tube at the fuel pump (11) to 28 N.m (20 ft. lbs.).
  6. Tighten the fuel tube at the fuel rail (8) to 5 N.m (44 in. lbs) plus an additional 75 degrees.
  7. Install the fuel quantity solenoid. Refer to SOLENOID, FUEL QUANTITY, INSTALLATION .
  8. Install the fuel tube clamp bolt (10) and tighten to 15 N.m (133 in. lbs.).
  9. Install the EGR cooler. Refer to COOLER, EGR, INSTALLATION .
  10. Install the engine cover and tighten the four nuts to 7 N.m (62 in. lbs).
  11. Connect the negative battery cable.
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