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Home >> Chrysler >> 2011 >> 300 C, 4WD >> Repair and Diagnosis >> External Pages >> Different car >> Section 538 (Fuel System - 1500) >> Fuel Delivery, Diesel >> Tube(S), Fuel >> Removal >> Fuel Tubes

Fuel Tubes

WARNING: This page is about a different car, the 2014 RAM 1500. However, it is still accessible from the selected car via links, so may be relevant.
WARNING:

Observe the following precautions when working on fuel systems: No sparks, open flames or smoking. Avoid inhaling and swallowing fuel. Avoid eye and skin contact with fuel. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing. Failure to observe these precautions may result in fire, explosion, property damage, and serious or fatal injury.

WARNING:

High-pressure lines deliver diesel fuel under extreme pressure from the injection pump to the fuel injectors. This may be as high as 2000 bar (29, 008 psi). Use extreme caution when inspecting for high-pressure fuel leaks. Fuel under this amount of pressure can penetrate skin causing personal injury or death. Inspect for high-pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system.

NOTE:

When key is cycled to the off position, fuel system pressure automatically bleeds down.

Fig 1: Removing/Installing Engine Cover
GC0158138Courtesy of CHRYSLER GROUP, LLC
  1. Disconnect the negative battery cable.
  2. Remove the engine cover (1).
    Fig 2: Removing/Installing Intake Manifold Silencer
    GC0157987Courtesy of CHRYSLER GROUP, LLC
  3. Remove the intake manifold silencer (2).
    Fig 3: Turbocharger & Charge Air Cooler (CAC) Hose
    GC0152123Courtesy of CHRYSLER GROUP, LLC
  4. Disconnect the Charge Air Cooler (CAC) hose (2) from turbocharger (1).
    Fig 4: Left Side Fuel Injector Silencer
    GC0152124Courtesy of CHRYSLER GROUP, LLC
  5. Remove the left bank fuel injector silencer (1).
    Fig 5: Right Side Fuel Injector Silencer
    GC0152125Courtesy of CHRYSLER GROUP, LLC
  6. Remove the right bank fuel injector silencer (1).
    Fig 6: Bolts & Engine Wire Harness Assembly
    GC0146844Courtesy of CHRYSLER GROUP, LLC
  7. Remove bolts (2) and pull up on the engine wire harness assembly (1) to release retainers from the intake manifold.
    Fig 7: Left Side Fuel Tubes & Union Nuts
    GC0146819Courtesy of CHRYSLER GROUP, LLC
  8. Unscrew union nuts (1 and 3) and remove and discard the left side fuel tubes (2).
  9. Install protective caps onto the fuel injectors and fuel rail.
    Fig 8: The Right Side Fuel Tubes
    GC0158181Courtesy of CHRYSLER GROUP, LLC
  10. Remove the EGR tube. Refer to TUBE, EXHAUST GAS RECIRCULATION (EGR), REMOVAL .
  11. Unscrew union nuts (1 and 3) and remove and discard the right side fuel tubes (2).
  12. Install protective caps onto the fuel injectors and fuel rail.
    Fig 9: Right & Left High Pressure Fuel Tubes & Union Nuts
    GC0146740Courtesy of CHRYSLER GROUP, LLC
  13. Remove nut (1) securing the right high pressure tube (3) to cylinder head cover.
  14. Remove union nuts (2, 4) and the right high pressure fuel tube (3), discard fuel tube.
  15. Remove bolt (6) securing the crossover tube (7) to top of intake manifold.
  16. Loosen union nuts (5, 8) and remove the high pressure fuel crossover tube (7), discard fuel tube.
  17. Remove bolt (9) securing the left side high pressure tube (11) to EGR air flow control valve.
  18. Loosen union nuts (10, 12) and remove the left high pressure fuel tube (11), discard fuel tube.
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