2014 Jeep Wrangler JK Factory Service Manual 14 - Fuel System

TUBE(S), Fuel

DESCRIPTION


Low-Pressure Lines Are:


High-Pressure Lines Are:

WARNING:

High-pressure fuel lines deliver fuel under extreme pressure from the injection pump to the injectors. This may be 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.

OPERATION


High-Pressure Lines

CAUTION:

The high-pressure fuel lines cannot contact each other or other components. Do not attempt to weld high-pressure fuel lines or to repair lines that are damaged. If lines are ever kinked or bent, they must be replaced. Use only the recommended lines when replacement of high-pressure fuel line is necessary.

High-pressure fuel lines deliver fuel (under pressure) of up to approximately 1800 bar (26,106 psi) from the injection pump to the fuel injectors. The lines expand and contract from the high-pressure fuel pulses generated during the injection process. 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:

Use extreme caution when inspecting for high-pressure fuel leaks. Inspect for high-pressure fuel leaks with a sheet of cardboard. High fuel injection pressure can cause personal injury if contact is made with the skin.

DIAGNOSIS AND TESTING - HIGH-PRESSURE FUEL LINE LEAKS

WARNING:

Due to extreme fuel pressures of up to 1800 bar (26,106 psi), use extreme caution when inspecting for high-pressure fuel leaks. Do not get your hand or a finger near a suspected leak. Inspect for high-pressure fuel leaks with a sheet of cardboard (2) (typical picture). High fuel injection pressure can cause personal injury if contact is made with the skin.

CAUTION:

The high-pressure fuel lines cannot contact each other or other components. Do not attempt to weld high-pressure fuel lines or to repair lines that are damaged. Only use the recommended lines when replacement of high-pressure fuel line is necessary.

High-pressure fuel line leaks can cause starting problems and poor engine performance.

Start the engine. Move the cardboard (2) over the suspected high-pressure fuel line leak, and check for fuel spray onto the cardboard. If line is leaking, retightening line while engine is shutdown. Replace damaged, restricted or leaking high-pressure fuel lines with the correct replacement line.

REMOVAL

CAUTION:

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. DO NOT use any lubricating or sliding agents that contain water.


CAUTION:

WHEN LOOSENING OR TIGHTENING HIGH-PRESSURE LINE FITTINGS 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.

  1. Disconnect the negative battery cable battery.

    2.  
  2. Remove the four nuts and the engine cover.

    3.  
  3. Disconnect fuel tube fittings (4) and (6) and remove four fuel tubes (5) and install a protective caps on the fuel injector and fuel rail.

    4.  
  4. Remove the EGR cooler (Refer to 07 - Cooling/Engine/COOLER, EGR - Removal) .

    5.  
  5. Remove bolt securing high pressure tube (10) to intake manifold.

    6.  
  6. Remove the fuel quantity solenoid (Refer to 14 - Fuel System/Fuel Delivery/SOLENOID, Fuel Quantity - Removal) .

    7.  
  7. Disconnect rail-to-injection pump high-pressure fuel tube fittings (8) and (11) and remove and discard the fuel tube (9).

    8.  

INSTALLATION

CAUTION:

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. DO NOT use any lubricating or sliding agents that contain water.


CAUTION:

WHEN LOOSENING OR TIGHTENING HIGH-PRESSURE LINE FITTINGS 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.



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. When ever a fuel tube connection is loosened, new fuel tubes MUST be used.

  1. Remove the protective caps from the fuel injectors and install new high pressure fuel tubes (5). Only hand tighten the high pressure fuel line (4) and (6).

    2.  
  2. Tighten the high pressure fuel tube (4) on the fuel injector to 28 N·m (20 ft. lbs.).

    3.  
  3. Tighten the high pressure fuel tube (6) on the fuel rail to 5 N·m (44 in. lbs) plus an additional 75 degrees.

    4.  
  4. Install the new fuel tube (9) and connect rail-to-injection pump high-pressure fuel line fittings (8) and (11).

    5.  
  5. Tighten the high pressure fuel feed tube at the high pressure pump (11) to 28 N·m (20 ft. lbs.).

    6.  
  6. Tighten the high pressure fuel feed tube at the fuel rail (8) to 5 N·m (44 in. lbs) plus an additional 75 degrees.

    7.  
  7. Install the fuel quantity solenoid (Refer to 14 - Fuel System/Fuel Delivery/SOLENOID, Fuel Quantity - Installation) .

    8.  
  8. Install fuel tube clamp bolt (10). Tighten to 15 N·m (133 in. lbs.).

    9.  
  9. Install the EGR cooler (Refer to 07 - Cooling/Engine/COOLER, EGR - Installation) .

    10.  
  10. Install the engine cover and securely tighten the four nuts.

    11.  
  11. Connect the negative battery cable.

    12.