Ram Truck 1500, 2500 & 3500 (2006-2008)

Fuel Pressure Limiting Valve

Print

Removal & Installation



5.9L Engine

The fuel pressure limiting valve is located on the top of the fuel rail.


WARNING
Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only.

  1. Thoroughly clean area at pressure limiting valve.
  2.  
  3. Remove banjo bolt from the banjo fitting.
  4.  
  5. Remove pressure limiting valve from fuel rail.
  6.  

To install:

  1. Be sure both top of manifold and limiting valve are clean.
  2.  
  3. Install valve and torque to 52 ft. lbs. (70 Nm).
  4.  
  5. Assemble the banjo bolt and new sealing washers to limiting valve.
  6.  
  7. Tighten the banjo bolt to 18 ft. lbs. (24 Nm).
  8.  

6.7L Engine

The fuel pressure limiting valve is screwed into the front of the fuel rail.

The fuel pressure limiting valve drain port is located on the side of the fuel rail next to the limiting valve. The drain port is not serviceable.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Thoroughly clean area at pressure limiting valve.
  4.  
  5. To gain access to the limiting valve, the intake connection/EGR valve assembly must be removed. Loosen clamp securing EGR crossover tube to EGR valve. Also loosen opposite end of EGR crossover tube. Remove clamp from intake connection.
  6.  
  7. Remove six bolts securing intake connection. Lift the entire EGR valve/intake connection up and to the side to gain access to fuel pressure limiting valve.
  8.  
  9. Discard the gasket.
  10.  
  11. Remove pressure limiting valve from fuel rail.

    Click image to see an enlarged view

    Fig. Fuel pressure limiting valve (1), fuel rail (2) fuel pressure sensor (3)

  12.  

To install:

  1. Be sure both end of manifold and limiting valve mounting area are clean.
  2.  
  3. Lubricate O-ring on limiting valve with fresh diesel oil. Also lubricate limiting valve threads with fresh diesel oil.
  4.  
  5. Install valve and tighten to 74 ft. lbs. (100 Nm). To prevent leaks, valve must be tightened to prescribed torque.
  6.  
  7. Install new intake connection gasket.
  8.  
  9. Position EGR valve/intake connection and install six bolts. Tighten bolts to 18 ft. lbs. (24 Nm).
  10.  
  11. Install new EGR crossover tube gasket. Tighten crossover tube clamps to 88 in. lbs. (10 Nm).
  12.  
  13. Using a diagnostic scan tool, reset vale life by using the (Reset Two-Stage Dump Valve Accumulator) function in the PCM portion of the diagnostic scan tool.
  14.  
  15. Start engine and check for leaks.
  16.  

 
label.common.footer.alt.autozoneLogo