Removal And Installation

WARNING: This page is about a different car, the 2019 RAM 3500 HD and 2019 RAM 2500 HD. However, it is still accessible from the selected car via links, so may be relevant.

REMOVAL

CAUTION:

Cleanliness cannot be over emphasized 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.

NOTE:

Be sure to cap or cover any part of the fuel system after disassembly using (special tool #2065600140, Protection Kit, Caps & Covers).

Disconnect and isolate the negative battery cable(s). Refer to STANDARD PROCEDURE .
Remove the engine cover. Refer to COVER, ENGINE, REMOVAL AND INSTALLATION, 6.7L .

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Cut the cable tie and position aside the bulk head connector (1).
Remove the fuel rail noise silencer. Refer to SILENCER, FUEL RAIL NOISE, REMOVAL AND INSTALLATION .

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Remove the bolt (3) securing the oil dipstick tube (4).
Remove the bolt securing the oil dipstick tube to the fuel rail and position the dip stick tube to the side to allow for clear access.
Thoroughly clean the fuel tubes at both ends.
CAUTION:
When loosening or tightening high-pressure line fittings attached to a separate fitting (5), use a back-up wrench on fitting (5). Do not allow fittings (5) to rotate. Damage to both fuel line and fitting will result.

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If removing fuel tube at No. 6 cylinder, a bracket (3) is located above fuel tube connection at cylinder head. Two bolts (2) secure this bracket to rear of cylinder head. The upper bolt hole is slotted. Loosen (but do not remove) these two bracket bolts. Tilt bracket down to gain access to No. 6 fuel line connection.
If removing fuel tube at either No. 1 or No. 2 cylinder, the intake manifold need to be removed first. Remove the intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL AND INSTALLATION, 6.7L .
If removing the high pressure pump to rail tubes (16 and 17), first remove nut (1) and bolt (7).
Place shop towels around fuel tubes at fuel rail and injectors. If possible, do not allow fuel to drip down side of engine.
NOTE:
Rail-to-cylinder head fuel tubes are marked on the cylinder head side nut with cylinder number identification.

NOTE:
Cylinder No. 3 fuel tube (12) is equipped with two vibration isolators (18). Do not remove or change the position of vibration isolators (18).
Carefully remove each fuel tube from engine. Note position of each while removing. Do not bend lines while removing.

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If required, remove the fuel return tube banjo bolts (2, 3, 4) and discard sealing washers.
If required, carefully remove the fuel return tube (1) from the engine.

INSTALLATION

CAUTION:

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If all six rail-to-cylinder head fuel tubes were removed and are being reinstalled, loosen the fuel rail mounting bolts before reinstalling the fuel tubes to allow for proper alignment of the fuel tubes and fuel rail. Do not remove the fuel rail.
CAUTION:
Anytime a high-pressure fuel tube is removed from the engine, its fuel connector retaining nut (5) at the cylinder head must first be re-torqued to prevent a leak between the high pressure connector and fuel injector inside the cylinder head.

CAUTION:
When loosening or tightening high-pressure line fittings attached to a separate fitting (5), use a back-up wrench on fitting (5). Do not allow fittings (5) to rotate. Damage to both fuel line and fitting will result.
Tighten the connector nuts (5) at the cylinder head to the proper specification. Refer to TORQUE SPECIFICATIONS- 6.7L .
NOTE:
Use care not to bend fuel tubs when installing.

NOTE:
Rail-to-cylinder head fuel tubes are marked on the cylinder head side nut with cylinder number identification.

NOTE:
Cylinder No. 3 fuel tube (12) is equipped with two vibration isolators (18). Do not remove or change the position of vibration isolators (18).
Install proper fuel tube to proper injector on engine. Tighten the fittings hand tight at both ends of tube.
Tighten fuel tube nut at the cylinder head to the proper specification. Refer to TORQUE SPECIFICATIONS- 6.7L . If all 6 fuel tubes are being installed, tighten the fuel tube nuts in the following sequence: 6-5-4-3-2-1.
Tighten fuel tube nuts at the fuel rail to the proper specification. Refer to TORQUE SPECIFICATIONS- 6.7L . If all 6 fuel tubes are being installed, tighten the fuel tube nuts in the following sequence: 6-5-4-3-2-1.
If loosened, tighten the fuel rail mounting bolts (6) to the proper specification. Refer to TORQUE SPECIFICATIONS- 6.7L .
If necessary, install both high-pressure fuel injection pump-to-fuel rail tubes (16 & 17). Initially finger tighten both fuel tube union nuts at the pump and the fuel rail.
Tighten both high-pressure fuel injection pump-to-fuel rail fuel tubes at the pump first and then at the rail. Tighten the union nuts to the proper specification. Refer to TORQUE SPECIFICATIONS- 6.7L .
Install the high-pressure fuel injection pump-to-fuel rail supply line bracket mounting nut (1) and tighten to the proper specification. Refer to TORQUE SPECIFICATIONS- 6.7L .
Tighten the bolt (7) to the proper specification. Refer to TORQUE SPECIFICATIONS- 6.7L .

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If removed, install the fuel return tube (1) using NEW sealing washers and initially hand tighten the fuel return tube banjo bolts (2, 3, 4). Next, tighten the fuel return tube banjo bolts to the proper, first at the rail (2), then at the cylinder head (3), and finally at the filter support bracket (4). Refer to TORQUE SPECIFICATIONS .

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If necessary, tilt metal bracket (1) upward and tighten two bolts (2) at rear of cylinder head to the proper specification. Refer to TORQUE SPECIFICATIONS- 6.7L .
If necessary, install intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL AND INSTALLATION, 6.7L .

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Reposition dip stick tube (4) in original position ensuring it is seated properly in the block, install fuel rail mounting bolt and tighten to the proper specification. Refer to TORQUE SPECIFICATIONS- 6.7L .
Tighten the bolt (4) to the proper specification. Refer to TORQUE SPECIFICATIONS- 6.7L .
Install the fuel rail noise silencer. Refer to SILENCER, FUEL RAIL NOISE, REMOVAL AND INSTALLATION .

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Position the bulk head connector (1) and install a NEW cable tie to secure.
Install the engine cover. Refer to COVER, ENGINE, REMOVAL AND INSTALLATION, 6.7L .
Connect the negative battery cable(s). Refer to STANDARD PROCEDURE -->.
Prime the fuel system. Refer to STANDARD PROCEDURE .
Start engine and check for leaks.