Chrysler RAM50/D50/Arrow 1979-1993 Repair Guide

Injection Lines



See Figure 1

If a fuel line under the hood should become damaged or leaky, do not attempt to weld or repair it. Replacement is required in all situations. Before disassembling any of the lines, mark the location of the plastic or metal clamps which hold the lines. These clamps are important in suppressing vibration which may loosen or damage the lines. Clamps must be reinstalled in the exact position from which they were removed.

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Fig. Fig. 1: The fuel and vapor line assembly and component location-2.3L diesel engines

  1. Clean all the connections carefully. Dirt is the enemy of the diesel fuel system.
  3. Mark the position of all the line clamps and brackets.
  5. Loosen each end of each line at both the injector and the pump. Remove the lines as an assembly with the clamps intact.
  7. Immediately plug the fittings on the injection pump and the injectors to keep out dirt. This is very important.
  9. Disassemble the lines on the workbench, replacing the damaged line(s).
  11. When reinstalling, assemble the lines with the clamps correctly placed on the workbench.
  13. Remove the plugs from the pump and injector ports. Install the fuel line assembly and start each threaded fitting by hand. Tighten each fitting to 20 ft. lbs. (27 Nm).
  15. Double check that the line clamps are in place and secure. Bleed the fuel system.
  17. Start the engine and check each joint for leaks. Because the system was open, it may require a few seconds until it runs smoothly.