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TUBE(S), Fuel: Installation: Installation

WARNING:

HIGH-PRESSURE FUEL LINES DELIVER FUEL UNDER EXTREME PRESSURE FROM THE INJECTION PUMP TO THE INJECTORS. THIS MAYBE AS HIGH AS 1800 BAR (26, 106 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 HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF CARDBOARD. WEAR SAFETY GOGGLES AND ADEQUATE PROTECTIVE CLOTHING WHEN SERVICING FUEL SYSTEM.

WARNING:

NO SPARKS, OPEN FLAMES OR SMOKING. RISK OF POISONING FROM INHALING AND SWALLOWING FUEL. RISK OF INJURY TO EYES AND SKIN FROM CONTACT WITH FUEL. POUR FUELS ONLY INTO SUITABLE AND APPROPRIATELY MARKED CONTAINERS. WEAR PROTECTIVE CLOTHING.

Fig 1: Identifying Fuel Injectors, High Pressure Fuel Tubes, Fuel Rail & High Pressure Feed Line
GC0137901Courtesy of CHRYSLER LLC
NOTE:

Any time a high pressure fuel tube has been loosened or disconnected, that high pressure fuel tube must be replaced.

  1. Remove the protective caps from the fuel rail and fuel injectors.
  2. Install a new high pressure fuel tubes (2) at fuel injectors (1) and fuel rail (3).
  3. Tighten the high pressure fuel tubes (2) at fuel injectors (1) to 7 N.m (62 in. lbs.).
  4. Tighten the high pressure fuel tubes (2) and fuel rail (3) to 7 N.m (62 in. lbs.).
  5. Tighten the high pressure fuel tubes (2) at fuel injectors (1) to 33 N.m (24 ft. lbs.).
  6. Tighten the high pressure fuel tubes (2) and fuel rail (3) to 33 N.m (24 ft. lbs.).
    Fig 2: Identifying Lock Tabs & Engine Wire Harness
    GC0137898Courtesy of CHRYSLER LLC
  7. Reposition the engine wire harness and push down to lock tabs.
    Fig 3: Identifying Glow Plug Module Harness Connector, Bolts & Turbocharger Exhaust Temperature Sensor Harness Connector
    GC0137897Courtesy of CHRYSLER LLC
  8. Connect the glow plug module harness connector (1).
  9. Reposition ground wires and tighten bolts (3) to 9 N.m (80 in. lbs.).
  10. Connect the turbocharger exhaust temperature sensor harness connector (2) to bracket.
    Fig 4: Identifying Turbocharger Exhaust Temperature Sensor Harness Connector
    GC0137896Courtesy of CHRYSLER LLC
  11. Connect the turbocharger exhaust temperature sensor (1) harness connector.
    Fig 5: Identifying Turbocharger Actuator Harness Connector
    GC0137895Courtesy of CHRYSLER LLC
  12. Connect the turbocharger actuator (1) harness connector.
    Fig 6: Identifying Camshaft Position Sensor (CMP) Harness Connector & Fuel Injector Harness Connectors
    GC0137894Courtesy of CHRYSLER LLC
  13. Position the fuel injector wire harness and push down to lock in place.
  14. Connect the fuel injector (2) harness connector.
  15. Connect the Camshaft Position Sensor (CMP) (1) harness connector.
  16. Connect negative battery cable.
  17. Start engine and inspect for leaks.
  18. Install engine cover.
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