Installation instructions for the BD high-pressure common-rail fuel line kit for 2007.5-2018 Dodge 2500HD/3500HD/4500/5500 Cummins 6.7L ISB trucks. The kit includes all six injector feed lines for a complete, direct fit with no need to reuse the factory lines.

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Introduction

This kit contains all 6 injector feed lines for Dodge Cummins 6.7L ISB applications, designed to provide a complete, direct fit with no need for the end user to bend any lines.

Applications

• 2007.5–2018 Dodge 2500HD / 3500HD / 4500 / 5500
• Cummins 6.7L ISB common-rail engine
• BD part #1050150 (Dodge 6.7L HP Fuel Line Kit)

Kit Contents

• 1501156 — Fuel line, Cylinder 1 (Qty: 1)
• 1501157 — Fuel line, Cylinder 2/3 (Qty: 2)
• 1501158 — Fuel line, Cylinder 4/5 (Qty: 2)
• 1501159 — Fuel line, Cylinder 6 (Qty: 1)

Tools Required

• Cable tie
• 8, 10 and 11 mm sockets
• 24 mm wrench
• 19 mm crowfoot
• Torque wrench
• Ratchet and ratchet extensions

Torque Specifications

• Fuel tube nut at the cylinder head — 40 N·m (30 ft-lbs)
• Fuel tube nuts at the rail — 40 N·m (30 ft-lbs)
• Metal bracket at the rear of the cylinder head — 43 N·m (32 ft-lbs)
• Oil dipstick bolt — 24 N·m (18 ft-lbs)
• Oil dipstick nut — 9 N·m (80 in-lbs)
• Engine cover bolts — 10 N·m (89 in-lbs)

Disassembly

1. Remove the engine oil dipstick (2). Remove the bolts (1) and lift off the engine cover (3).

   

2. Cut the cable tie and move aside the bulkhead connector (1).

   

3. Disconnect the exhaust pressure sensor wire harness connector (2), then the EGR cooler bypass valve wire harness connector (1).

   

4. Disconnect the crankcase pressure sensor 2 wire harness connector (1).

   

5. Disconnect the crankcase pressure sensor 1 wire harness connectors (7).

   

6. Disconnect both fuel injector harness connectors (1).

   

7. Remove the CCV (crankcase ventilation) oil drain hoses (1, 2) from the cylinder head cover.

   

8. Remove the fuel tube silencer (1).

   

9. Remove the intake manifold.
10. Remove the bracket (5) located above the fuel tube connection at the cylinder head. Two bolts (4) secure this bracket to the rear of the cylinder head; the upper bolt hole is slotted. Loosen — but do not remove — these two bracket bolts, then tilt the bracket down.
11. Remove the fuel injector lines. Refer to the diagram below for the rail, fittings, and bracket layout.
    WARNING: When loosening or tightening the high-pressure lines attached to a separate fitting (13), use a backup wrench on the fitting. Do not allow the fittings to rotate — damage to both the fuel line and the fitting will result.

    

Installing the New Fuel Lines

Installation is the reverse of the disassembly procedure. Reinstall the new injector feed lines, intake manifold, fuel tube silencer, CCV hoses, bracket and all harness connectors, then tighten to the following torque specifications:

• Fuel tube nut at the cylinder head — 40 N·m (30 ft-lbs)
• Fuel tube nuts at the rail — 40 N·m (30 ft-lbs)
• Metal bracket at the rear of the cylinder head — 43 N·m (32 ft-lbs)
• Oil dipstick bolt — 24 N·m (18 ft-lbs); nut — 9 N·m (80 in-lbs)
• Engine cover bolts — 10 N·m (89 in-lbs)

Fuel System Priming

1. Turn the key to the CRANK position and quickly release it to the ON position before the engine starts. This operates the fuel transfer (lift) pump for 25 seconds.

   

2. Crank the engine. If it does not start after 25 seconds, turn the key to OFF and leave it for at least 10 seconds, then repeat the previous step until the engine starts. Fuel system priming is now complete.
3. Attempt to start the engine. When the engine does start, it may run erratically and be noisy for a few minutes — this is normal. If the engine fails to start, proceed to the steps below.

If the Engine Still Will Not Start

1. Repeat the fuel priming procedure using the fuel transfer (lift) pump. Be sure fuel is present at the fuel tank.
2. Crank the engine for 30 seconds at a time to allow the fuel system to prime.

Final Inspection