Chrysler 300/300 Touring/300C, Dodge Magnum. Manual — part 1756
FUEL LINES
DESCRIPTION - FUEL LINES/HOSES AND CLAMPS
Also refer to Quick-Connect Fittings.
WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE
MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE IN THIS GROUP.
THIS MAY RESULT IN PERSONAL INJURY OR DEATH.
The lines/tubes/hoses used on fuel injected vehicles are of a special construction. This is due to the higher fuel
pressures and the possibility of contaminated fuel in this system. If it is necessary to replace these lines/tubes/
hoses, use new original equipment lines/tubes/hoses.
If equipped: The hose clamps used to secure rubber hoses on vehicles are of a special rolled edge construction.
This construction is used to prevent the edge of the clamp from cutting into the hose. Only these rolled edge type
clamps may be used in this system. All other types of clamps may cut into the hoses and cause leaks.
Use new original equipment type hose clamps.
STANDARD PROCEDURE - HOSES AND CLAMP
Inspect all hose connections (clamps and quick connect fittings) for completeness and leaks. Replace cracked,
scuffed, or swelled hoses. Replace hoses that rub against other vehicle components or show sign of wear.
Fuel injected vehicles use specially constructed hoses. When replacing hoses, only use hoses marked EFM/EFI.
When installing hoses, ensure that they are routed away from contact with other vehicle components that could rub
against them and cause failure. Avoid contact with clamps or other components that cause abrasions or scuffing.
Ensure that rubber hoses are properly routed and avoid heat sources.
The hose clamps have rolled edges to prevent the clamp from cutting into the hose. Only use clamps that are
original equipment or equivalent. Other types of clamps may cut into the hoses and cause high pressure fuel leaks.
Tighten hose clamps to 1 N·m (9 in. lbs.) torque.
Inspect all hose connections such as clamps, couplings and fittings to make sure they are secure and leaks are not
present. The component should be replaced immediately if there is any evidence of degradation that could result in
failure.
Never attempt to repair a plastic fuel line/tube. Replace as necessary.
Avoid contact of any fuel tubes/hoses with other vehicle components that could cause abrasions or scuffing. Be sure
that the plastic fuel lines/tubes are properly routed to prevent pinching and to avoid heat sources.
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FUEL DELIVERY
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FUEL DELIVERY - DIESEL
TABLE OF CONTENTS
page
page
FUEL DELIVERY - DIESEL
TORQUE - DIESEL . . . . . . . . . . . . . . . . . . . . . . . . . 101
SEPARATOR-FILTER FUEL AND WATER
PUMP-HIGH PRESSURE FUEL
SENSOR-WATER IN FUEL
FITTING-QUICK CONNECT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
LINES-HIGH PRESSURE
TANK-FUEL
MODULE-FUEL PUMP
SENSOR-FUEL LEVEL SENDING UNIT
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FUEL DELIVERY - DIESEL
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FUEL DELIVERY - DIESEL
STANDARD PROCEDURE
FUEL CONTAMINATION
If a diesel engine’s fuel supply has been contaminated with gasoline, the following procedure must be followed:
1. Remove all fuel from the fuel tank. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE-
DRAINING FUEL TANK) Use an appropriate fuel container. Dispose of the contaminated fuel using the proper
procedures.
CAUTION: Dispose of petroleum based products in a manner consistent with all applicable Local, State,
Federal, and Provincial regulations.
2. Remove and clean fuel tank. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL TANK - REMOVAL)
3. Install the fuel tank. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL TANK - INSTALLATION)
4. Fill fuel tank with fresh diesel fuel.
5. Drain and remove the fuel filter. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL FILTER / WATER SEP-
ARATOR - REMOVAL)
6. Install a new fuel filter. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL FILTER / WATER SEPARATOR -
INSTALLATION)
7. Check the engine control module for any diagnostic trouble codes (DTCs). Record and clear any DTCs that are
present.
8. Start and run the engine. Run the engine for up to 15 minutes to allow time for any DTCs to reset and shut off
the engine.
9. Check the engine control module for any diagnostic trouble codes (DTCs). Record any DTCs that are present.
Refer to the appropriate engine electrical diagnostics to diagnose any DTCs that were set.
CAUTION: With the high pressure fuel system in this vehicle, any residual contaminated fuel will be
removed very quickly. Shut off the engine immediately if signs of engine damage are noted.
The engine should then be evaluated to determine if the contaminated fuel has caused any damage to the fuel
system and/or engine. Indicators that the fuel system has been damaged include the following:
•
Unstable fuel rail pressure. This can manifest itself as instability of idle speeds, excessive undershoot/over-
shoot at engine start-up, or excessive undershoot/overshoot when the engine operating conditions change. A
typical engine response to a large rail pressure undershoot would be a decrease in engine speed or engine
stall.
•
Excessive noise from the engine. This could indicate poor rail pressure control or the inability of the injection
system to inject the proper amount of fuel.
•
Excessive smoke (black or white). This could indicate the inability of the fuel system to inject the proper
amount of fuel.
NOTE: If any of these conditions are exhibited after cleaning the fuel system, proceed to the appropriate
engine electrical diagnostic information. Repair the fuel system and/or engine as necessary.
BLEEDING AIR FROM FUEL SYSTEM
WARNING: No sparks, open flames or smoking. Risk of poisoning from inhaling and swallowing fuel. Risk
of injury to eyes and skin from contact with fuel. Pour fuels only into suitable and appropriately marked
containers. Wear protective clothing.
1. Turn the ignition off.
2. Remove engine cover.
3. Connect a hose to the fuel filter air bleed port and insert the remaining end into a approved and appropriately
marked container.
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FUEL DELIVERY - DIESEL
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4. Turn the air bleed counterclockwise to open the air bleed.
CAUTION: Turning the ignition to the on position will engage the in tank fuel pump. Be sure that the bleed
hose and the fuel capture container is secure.
5. Turn the ignition to the on position and observe the container until fuel flows free of bubbles.
6. Turn the ignition off.
7. Tighten the bleed valve on the fuel filter.
8. Remove the bleed hose and container.
9. Install engine cover.
DRAINING FUEL TANK - DIESEL
A one-way check valve is located within the fuel fill fitting on the fuel tank. Because of this valve, the tank cannot
be drained the conventional way through the fuel fill opening.
To drain the tank, the fuel pump module must be removed.
1. Remove fuel tank (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL TANK - REMOVAL).
2. Remove fuel pump module (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL PUMP MODULE - REMOVAL).
3. After fuel pump module has been removed, drain fuel into an approved diesel fuel oil draining station.
SPECIFICATIONS
TORQUE - DIESEL
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Screw, Water in Fuel
Sensor
1.5
-
13
Nut, High Pressure Fuel
Line
22
-
195
Bolt, Fuel Rail
14
-
124
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