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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.

Fig 1: Right & Left High Pressure Fuel Tubes & Union Nuts
GC0146740Courtesy of CHRYSLER GROUP, LLC
NOTE:

Fuel tubes are a one time only use and must be replaced anytime they have been removed.

  1. Install the new left high pressure fuel tube (11) and tighten union nuts (10, 12) finger tight:
    • Tighten union nut (10) to 5 N.m (44 in. lbs.) plus an additional 75 degrees turn.
    • Tighten union nut (12) to 11 N.m (97 in. lbs.) plus an additional 75 degrees turn.
  2. Install bolt (9) securing the left side high pressure tube (11) to EGR air flow control valve and tighten to 11 N.m (97 in. lbs.).
  3. Install the new high pressure fuel crossover tube (7) and tighten union nuts (5, 8) finger tight:
    • Tighten union nut (5, 8) to 5 N.m (44 in. lbs.) plus an additional 75 degrees turn.
  4. Install bolt (7) securing the high pressure crossover tube (7) to intake manifold and tighten to 11 N.m (97 in. lbs.).
  5. Install the new right high pressure fuel tube (3) and tighten union nuts (2, 4) finger tight:
    • Tighten union nut (4) to 5 N.m (44 in. lbs.) plus an additional 75 degrees turn.
    • Tighten union nut (2) to 11 N.m (97 in. lbs.) plus an additional 75 degrees turn.
  6. Install nut (1) securing the right side high pressure tube (3) to right side cylinder head cover and tighten to 11 N.m (97 in. lbs.).
    Fig 2: The Right Side Fuel Tubes
    GC0158181Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Fuel tubes are a one time only use and must be replaced anytime they have been removed.

  7. Remove the protective caps from the fuel injectors and fuel rail.
  8. Install the new right side fuel tubes (2) and tighten union nuts (1, 3) finger tight:
    • Tighten union nut (1) to 5 N.m (44 in. lbs.) plus an additional 75 degrees turn.
    • Tighten union nut (3) to 11 N.m (97 in. lbs.) plus an additional 75 degrees turn.
  9. Install the EGR tube. Refer to TUBE, EXHAUST GAS RECIRCULATION (EGR), INSTALLATION .
    Fig 3: Left Side Fuel Tubes & Union Nuts
    GC0146819Courtesy of CHRYSLER GROUP, LLC
  10. Remove the protective caps from the fuel injectors and fuel rail.
  11. Install new left side fuel tubes (2) and tighten union nuts (1 and 3) finger tight.
    • Tighten union nut (1) to 5 N.m (44 in. lbs.) plus an additional 75 degrees turn.
    • Tighten union nut (3) to 11 N.m (97 in. lbs.) plus an additional 75 degrees turn.
    Fig 4: Bolts & Engine Wire Harness Assembly
    GC0146844Courtesy of CHRYSLER GROUP, LLC
  12. Install the engine wire harness assembly (1) to the intake manifold and push down to seat the wire harness retainers. Tighten bolts (2) to 11 N.m (97 in. lbs.).
    Fig 5: Left Side Fuel Injector Silencer
    GC0152124Courtesy of CHRYSLER GROUP, LLC
  13. Install the left bank fuel injector silencer (1).
    Fig 6: Turbocharger & Charge Air Cooler (CAC) Hose
    GC0152123Courtesy of CHRYSLER GROUP, LLC
  14. Disconnect the Charge Air Cooler (CAC) hose (2) from turbocharger (1).
    Fig 7: Removing/Installing Intake Manifold Silencer
    GC0157987Courtesy of CHRYSLER GROUP, LLC
  15. Install the right bank fuel injector silencer (1).
  16. Install the intake manifold silencer.
    Fig 8: Removing/Installing Engine Cover
    GC0158138Courtesy of CHRYSLER GROUP, LLC
  17. Install the engine cover (1).
  18. Connect negative battery cable.
  19. Start engine, allow to warm, turn engine off and inspect for leaks.
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