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2.0L Front Fuel Delivery Line: 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.

  1. Working from the engine compartment, install the front fuel delivery line and engage the retaining clips.
    GC0165117Courtesy of CHRYSLER GROUP, LLC
  2. Using a hydraulic lift, position the suspension crossmember. Install the left and right front mounting bolts (1) and tighten to the proper specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0164955Courtesy of CHRYSLER GROUP, LLC
  3. Install the suspension crossmember rear bolts (1) and tighten to the proper specification. Refer to TECHNICAL SPECIFICATIONS .
  4. Remove the hydraulic lift.
    GC0165909Courtesy of CHRYSLER GROUP, LLC
  5. Engage the fuel supply/return lines (1) into the retaining clip.
    GC0164971Courtesy of CHRYSLER GROUP, LLC
  6. Engage the fuel supply/return lines (1) into the retaining clips.
    GC0165275Courtesy of CHRYSLER GROUP, LLC
  7. Install the A/C suction and liquid lines retaining bracket and securely tighten the nut (1).
    GC0165205Courtesy of CHRYSLER GROUP, LLC
  8. Engage the A/C suction line (1c) into the retaining clip (1a) and connect the quick coupling (1b).
    GC0164548Courtesy of CHRYSLER GROUP, LLC
  9. Engage the A/C suction and liquid lines into the retaining clips (1).
    GC0166192Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The O-rings must be replaced for each A/C line that was disconnected, using only O-rings that are made for the type of refrigerant oil that is in the A/C system. Failure to replace the O-rings may result in a refrigerant leak.

  10. Install a NEW  O-rings on the A/C suction and liquid lines. Connect the lines to the expansion valve and tighten the nuts (1) to the proper specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0164790Courtesy of CHRYSLER GROUP, LLC
  11. Insert the fuel return pipe into the retaining clip (1) and connect the quick coupling (1).
    GC0178788Courtesy of CHRYSLER GROUP, LLC
  12. Connect the fuel supply (3) and return line (2) quick connect couplings.
  13. Engage the fuel lines into the retaining clip (1).
    GC0179344Courtesy of CHRYSLER GROUP, LLC
  14. Install the fuel line shield and securely tighten the bolts (1).
    GC0165506Courtesy of CHRYSLER GROUP, LLC
  15. Install the rear mount bolt (1) and tighten to the proper specification. Refer to TORQUE SPECIFICATIONS DIESEL  .
    GC0163476Courtesy of CHRYSLER GROUP, LLC
  16. Install the exhaust support bracket bolts (1) and tighten to the proper specification. Refer to TECHNICAL SPECIFICATIONS .
  17. Tighten the exhaust clamp nut (2) to the proper specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0165872Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Left side shown in illustration, right side similar.

  18. Install the right and left joint stabilizer bars to the shocks and tighten the nuts (1) to the proper specification. Refer to FRONT, TECHNICAL SPECIFICATIONS .
    GC0165085Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Left side shown in illustration, right side similar.

  19. Install the right and left lower load beams and tighten bolts (1) to the proper specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0164239Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Left side shown in illustration, right side similar.

  20. Install the fasteners (1) securing right and left lower load beams at the front end and tighten to the proper specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0165505Courtesy of CHRYSLER GROUP, LLC
  21. Using a NEW  bolt (1) install the steering column shaft to the steering gear and tighten to the proper specification. Refer to TECHNICAL SPECIFICATIONS .
  22. Install the air cleaner body. Refer to the appropriate Service Information .
  23. Install the fuel filter with bracket. Refer to FILTER, FUEL, REMOVAL AND INSTALLATION  .
  24. Install the right front wheelhouse splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE, REMOVAL AND INSTALLATION .
  25. Install the right front wheel. Refer to REMOVAL AND INSTALLATION .
  26. Install the front fascia. Refer to FASCIA, FRONT, REMOVAL AND INSTALLATION .
  27. Install the belly pan. Refer to BELLY PAN, REMOVAL AND INSTALLATION .
  28. Evacuate and charge the A/C system. Refer to PLUMBING, STANDARD PROCEDURE .
  29. Install the engine cover. Refer to the appropriate Service Information .
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