OEM 2006 Dodge Sprinter 2500 Fuel Rail

2006 Dodge Sprinter 2500 Fuel Rail Parts and Q&A

• Q: How to Service a Fuel Rail on 2006 Dodge Sprinter 2500?

  A: Service the fuel rail by unattaching the negative battery cable and taking off the engine cover. Then, remove and put aside the intake manifold air inlet duct. Remove the connector wires from the fuel rail pressure and control valve and take out the retaining bolts holding the engine harness onto the fuel rail. After removing the high-pressure lines and fuel rail bolts, keep a wrench on the unions and tighten in an alternating manner until the nuts are tight enough, but not so much that you damage the lines. Once you have removed your injures, seal the points of were your lines used to be and keep the area tidy. Disconnect the return flow line from the high-pressure pump at the rail and at the banjo bolt and then take out the fuel rail. Place the fuel rail on the cylinder head and turn each fastener by hand, but don't tighten it completely. Join the fuel pressure control valve harness connector to the fuel return lines at the banjo bolt, check the sealing cones and add new ones if required. Also, ensure all fuel pressure lines remain where they were installed. Handle the installation of fuel lines created for high pressure and tighten them with your hand. Before doing so, fasten a wrench at the thread and turn while tightening these nuts in a way that they do not cross the specified torque level. Once the fuel rail bolts are at 14 N.m (124 lbs in), attach the electrical connectors for the engine harness, join the intake manifold air duct and then hook up the negative battery cable. Be careful when placing the engine cover so that the fuel injector return hose clear bends around the banjo fitting at the rear-left section of the cover. Turn the engine on briefly, run it for a few minutes, shut it down and look for any leaks.