High Pressure Fuel Line Leaks

WARNING: High-pressure fuel lines deliver fuel under extreme pressure from the injection pump to the injectors. This maybe as high as 1600 bar (23,200 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 placed in the suspected area while the engine is not running. Start the vehicle and allow the engine to run for a short period. Turn the engine off and inspect the piece of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system.

Fig 1: Test For Fuel Line Leaks

Courtesy of CHRYSLER LLC

1 - HIGH-PRESSURE LINE

2 - CARDBOARD

3 - FITTING

High-pressure fuel line (1) leaks can cause starting problems and poor engine performance.

Turn the engine off.
Place a piece for cardboard (2) in the suspected area. See Fig 1.
Start the engine and allow to run for a short period.
Turn the engine off.
Inspect the cardboard.

If a high-pressure line connection is leaking, tighten the connection to specification then perform this procedure again. Replace any damaged, restricted or leaking high-pressure fuel lines with the correct replacement line.

CAUTION: The high-pressure fuel lines cannot contact each other or other components. Do not attempt to weld high-pressure fuel lines or to repair lines that are damaged. Only use the recommended lines when replacement of high-pressure fuel line is necessary.