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Rail, Fuel: Installation

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NOTE:

The "Fuel Adaptive Parameter Reset" and "Fuel Feed System Component Replacement" scan tool procedures should always be run after a PCM, fuel injector, fuel rail, high pressure pump or fuel pressure sensor is replaced. The procedures should be in the "Miscellaneous Functions" tab in the PCM. Failure to run the procedures may cause DTCs to set in the PCM.

  1. Lubricate the threads of the fuel rail pressure sensor with a medium hydraulic oil such as Mobil DTE-25 or equivalent.
  2. Install the fuel pressure sensor and tighten it the proper torque specification. Refer to (TORQUE SPECIFICATIONS ).
  3. Install the NEW  fuel injector seals on each injector, using the (special tool #2025500140, Kit, Fuel Injector) as described below.
    GC0181008Courtesy of CHRYSLER GROUP, LLC
  4. Insert the NEW  injector seal (1a) on the (special tool #2025501141, Cone, Injector Seal Installer 70mm) (1b) mounted on the injector (1c).
  5. Using the (special tool #2025502140, Installer, Injector Seal to Cone) (2a), slide the injector seal into the recess on the fuel injector (2b).
    GC0180989Courtesy of CHRYSLER GROUP, LLC
  6. Check that the injector seal is correctly fitted onto the injector (1a) with the (special tool #2025503140, Tool, Injector Seal Calibration) (1b). The tool has to install and remove freely without catching on the injector seal edge.
    GC0181006Courtesy of CHRYSLER GROUP, LLC
  7. Install the NEW  O-rings (1) on each injector.
  8. Lightly lubricate NEW  O-ring seals with engine oil.
    GC0181002Courtesy of CHRYSLER GROUP, LLC
  9. Install the injectors (1b) in the fuel rail and insert the suspension pins (1a).
    GC0181012Courtesy of CHRYSLER GROUP, LLC
  10. Install the retaining clips (1).
  11. Install and hand tighten the (special tool #2044400140, Guide, Fuel Rail Installer) (1) onto the cylinder head.
    GC0182562Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Do not  lubricate the new injector seals prior to installation into the cylinder head.

  12. Using the fuel rail guides, install the fuel rail and injectors.
  13. Tighten the fuel rail to cylinder head bolts (1) to the proper torque specification. Refer to (TORQUE SPECIFICATIONS ).
    NOTE:

    A NEW  high pressure fuel line MUST be installed any time it is disconnected.

  14. Install the a NEW  high pressure fuel line using the (special tool #2025508140, Wrench, Fuel Line 17mm) and tighten the fuel rail fitting and pressure pump fitting to the proper torque specification. Refer to (TORQUE SPECIFICATIONS ).
    NOTE:

    Using an offset torque adapter can affect the actual torque applied to the fittings depending on the length and angle of the adapter relative to the torque wrench.

  15. Connect the wire harness connections to the fuel injectors.
  16. Place the soundproofing panel back in position.
  17. Connect the wire harness connection of the fuel pressure sensor on the fuel rail.
  18. Install the ignition coils. Refer to INSTALLATION .
  19. Install the air outlet pipe. Refer to COOLER AND HOSES, CHARGE AIR, INSTALLATION .
  20. Install the side and top engine covers. Refer to COVER, ENGINE, INSTALLATION .
  21. Connect the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), connect the IBS connector.
  22. Check the high pressure fuel system for leaks. Refer to FUEL SYSTEM/FUEL DELIVERY/DIAGNOSIS AND TESTING .
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