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Home >> Chrysler >> 2011 >> 300 C, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1580 (Fuel System - 2500 Hd) >> Fuel Delivery, 6.7L Diesel >> Tube(S), Fuel >> Removal

Tube(S), Fuel: Removal

WARNING: This page is about a different car, the 2017 RAM 2500 HD. However, it is still accessible from the selected car via links, so may be relevant.
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.

GC0161582Courtesy of CHRYSLER GROUP, LLC
  1. Disconnect and isolate both of the negative battery cables.
  2. Remove the engine oil dipstick (2).
  3. Remove bolts (1) and the engine cover (3).
    GC0155445Courtesy of CHRYSLER GROUP, LLC
  4. Cut the cable tie and position aside the bulk head connector (1).
    GC0155426Courtesy of CHRYSLER GROUP, LLC
  5. Disconnect the exhaust pressure sensor wire harness connector (2).
  6. Disconnect the EGR cooler bypass valve wire harness connector (1).
    GC0155113Courtesy of CHRYSLER GROUP, LLC
  7. Disconnect the crankcase pressure sensor 2 wire harness connector (1).
    GC0110278Courtesy of CHRYSLER GROUP, LLC
  8. Disconnect crankcase pressure sensor 1 wire harness connectors (7).
    GC0155340Courtesy of CHRYSLER GROUP, LLC
  9. Disconnect both fuel injector harness connectors (1).
    GC0157560Courtesy of CHRYSLER GROUP, LLC
  10. Remove the CCV oil drains hoses (1, 2) from cylinder head cover.
    GC0157561Courtesy of CHRYSLER GROUP, LLC
  11. Remove the fuel tube silencer (1).
    GC0155293Courtesy of CHRYSLER GROUP, LLC
  12. Disconnect the fuel pressure sensor wire harness connector (2).
  13. Disconnect necessary wiring harness retention clips from intake manifold.
  14. Remove nut and bolt securing the oil dipstick tube.
  15. Thoroughly clean fuel tubes at both ends.
    CAUTION:

    When loosening or tightening high-pressure lines attached to a separate fitting (13), use a back-up wrench on fitting (12). Do not allow fittings (12) to rotate. Damage to both fuel line and fitting will result.

    GC0155209Courtesy of CHRYSLER GROUP, LLC
  16. If removing fuel tube at No. 6 cylinder, a bracket (5) is located above fuel tube connection at cylinder head. Two bolts (4) 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.
    NOTE:

    Before fuel tubes No. 1 or No. 2 can be removed the intake manifold need to be removed first. Remove the intake manifold. Refer to REMOVAL .

  17. If removing fuel tube at either No. 1 or No. 2 cylinder.
  18. Place shop towels around fuel tubes at fuel rail and injectors. If possible, do not allow fuel to drip down side of engine.
  19. Carefully remove each fuel tube from engine. Note position of each while removing. Do not bend lines while removing. 
  20. Remove the fuel return line banjo bolt at fuel rail and discard sealing washers.
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