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

Injection Lines

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Removal & Installation



5.9L Engine

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. Disconnect both negative battery cables from both batteries. Cover and isolate ends of cables.
  2.  
  3. Thoroughly clean fuel lines at both ends.
  4.  
  5. If removing fuel line at either No. 1 or No. 2 cylinder, the intake manifold air heater elements must first be removed from top of intake manifold.
  6.  
  7. If removing fuel line at No. 6 cylinder, a bracket is located above fuel line connection at cylinder head. Two bolts secure this bracket to rear of cylinder head. The upper bolt hole is slotted. Loosen (but do not remove) these 2 bracket bolts. Tilt bracket down to gain access to No. 6 fuel line connection.
  8.  
  9. Remove engine lift bracket (if necessary).
  10.  
  11. Remove necessary insulated fuel line support clamps and bracket bolts at intake manifold. DO NOT remove insulators from fuel lines.
  12.  
  13. Place shop towels around fuel lines at fuel rail and injectors. If possible, do not allow fuel to drip down side of engine.
    WARNING
    When loosening or tightening high-pressure lines attached to a separate fitting , use a back-up wrench on fitting. Do not allow fitting to rotate. Damage to both fuel line and fitting will result.

  14.  
  15. Carefully remove each fuel line from engine. Note position of each while removing. Do not bend lines while removing.
  16.  

To install:


NOTE
All high-pressure fuel lines are of the same length and inside diameter. Correct high-pressure fuel line usage and installation is critical to smooth engine operation.


WARNING
Anytime a high-pressure line is removed from the engine, its fuel connector nut at the cylinder head must first be retorqued.

  1. Tighten fuel lines at high pressure injector connector to 37 ft. lbs. (50 Nm).
  2.  
  3. Position fuel line support clamp(s) to fuel line(s). Install clamp nuts/bolts and tighten finger-tight.
  4.  
  5. Position the proper fuel line to the proper injector on engine. Tighten fittings hand tight at both ends of line.
  6.  
  7. Tighten fuel lines at fuel rail to 27 ft. lbs. (37 Nm).
  8.  
  9. Tighten clamp/support nuts and bolts.
  10.  
  11. Install engine lifting bracket and bolt. Tighten to 56 ft. lbs. 77 (Nm).
  12.  
  13. If fuel line at either Number 1 or Number 2 cylinder has been replaced, install intake manifold air heater elements to top of intake manifold.
  14.  
  15. If fuel line at Number 6 cylinder has been replaced, tilt metal bracket upward and tighten 2 bolts at rear of cylinder head to 32 ft. lbs. (43 Nm).
  16.  
  17. Install remaining fuel line support clamps and bracket bolts at intake manifold.
  18.  
  19. Connect both negative battery cables to both batteries.
  20.  
  21. Prime the fuel system. Refer to Fuel System Priming.
  22.  
  23. Check lines/fittings for leaks.
  24.  

6.7L Engine

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.


NOTE
If removing fuel line at either No. 1 or No. 2 cylinder, the air inlet housing/EGR valve assembly must first be removed from the top of the intake manifold.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect both negative battery cables from both batteries. Cover and isolate ends of cables.
  4.  
  5. Thoroughly clean fuel lines at both ends.
    WARNING
    When loosening or tightening high-pressure lines attached to a separate fitting, use a back-up wrench on fitting. Do not allow fittings to rotate. Damage to both fuel line and fitting will result.

  6.  
  7. If removing fuel line at No. 6 cylinder, a bracket (4) is located above fuel line connection at cylinder head. Two bolts (3) secure this bracket to rear of cylinder head. The upper bolt hole is slotted. Loosen (but do not remove) these two bracket bolts. Tilt bracket down to gain access to No. 6 fuel line connection.
  8.  
  9. If removing fuel line at either No. 1 or No. 2 cylinder, the air inlet housing/EGR assembly must first be removed from top of intake manifold. Refer to EGR valve removal for procedures.
  10.  
  11. Place shop towels around fuel lines at fuel rail and injectors. If possible, do not allow fuel to drip down side of engine.
  12.  
  13. Carefully remove each fuel line from engine. Note position of each while removing.
    NOTE
    Do not bend lines while removing.

  14.  

To install:


NOTE
All high-pressure fuel lines are of the same length and inside diameter. Correct high-pressure fuel line usage and installation is critical to smooth engine operation.


WARNING
Anytime a high-pressure line is removed from the engine, its fuel connector nut at the cylinder head must first be retorqued.

  1. Tighten nuts at high pressure injector connector nut at the cylinder head. Tighten nut to 37 ft. lbs. (50 Nm).
  2.  
  3. Position proper fuel line to proper injector on engine. Tighten fittings hand tight at both ends of line.
  4.  
  5. Tighten fuel line at cylinder head. Torque nut to 30 ft. lbs. (40 Nm).
  6.  
  7. Tighten fuel line nuts at fuel rail to 30 ft. lbs. (40 Nm).
  8.  
  9. If fuel line at No. 6 cylinder has been replaced, tilt metal bracket upward and tighten two bolts at rear of cylinder head. Tighten to 32 ft. lbs. (43 Nm).
  10.  
  11. If necessary, install EGR valve/air intake manifold assembly.
  12.  
  13. Connect both negative battery cables to both batteries.
  14.  
  15. Prime fuel system. Refer to Fuel System Priming.
  16.  
  17. Check lines/fittings for leaks.
  18.  

 
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