Hi all
I’m planning to lift the head off my 2004 2.5 CRD. I note in the workshop manual that any high pressure fuel lines that need to be disassembled during the process will need to be replaced with new lines. I don’t have a problem in buying new lines if required to do so, but on reading the few posts I can find on here regarding work on the head there is no mention of ever replacing the lines, only the obvious like new gaskets and head bolts.
I have also looked on sites specialising in remanufacturing heads that also supply fitting kits like gaskets, bolts etc but again no mention of high pressure fuel lines.
Is the manual just trying to get me through the dealer’s door or can the original lines be reused successfully, providing there is no damage to them.
I would be very interested to hear if any of you guys have experienced this matter.

Phil

I've reused the fuel lines, no problem. it's the black return lines i might be worried about, but if you're careful.. no worries!

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Harlan in Austin
2005 Jeep Liberty Sport CRD: Samco, No Muffller, EGR removed, Mechanical Fan Back On, Rancho RS5k's, Self Installed Rockers, Lifters, Engine Mounts, and Timing Belt, CCV to Airbox Mod, Hacked RB1, CD-Changer, AuxInput; 2005 PowerStroke Excursion 6.0: Rancho 9k's, SuperChipped, Stock otherwise. BioDiesel Maker.

Hi Galatron
thanks for that, i'll give it a go with the old lines it will help to shave a few pounds off the overall cost.
I suppose even if I do get problems later its no big deal to change them.

Phil

I had my head off 2000 miles ago and reused all the lines with zero issues. The factory manual did NOT mention replacing them.
You will be fine

Hi Gramurai
good information thank you. I was going to remove the head thinking I was loosing coolant there but did a chemical gas test today with a negative result, so thankfully may get away without lifting the head.

On that coolant leak run by a parts store and get some UV leak detector. Put that in the system and run for a few days then look for the dye with a UV light which you can get from Amazon for like $10. Amazing how much coolant you can lose from invisible leaks (coolant evaporates as it leaks) due to missing or weak coolant hose spring clamps or worm clamps not snugged down enough.

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Sold to LOST member my 05 Ltd, GDE Stg II turbo + TCM tune, SunCoast TC w. Transgo kit, Steiger window regulators, Samcos, Fumoto valve, 2nd gen filter head with Lub. Spec. bleeder, Hayden clutch & 11 blade fan, inverted spare, P-1 battery, BF Goodrich Long Trail TAs, Etecno1 glow plugs, timing belt at 50K miles/8 yrs

I had a coolant leak a while back that turned out to be hoses to the EGR valve. The hoses were cheap, labor to get to them and replace not so much.

I dont think that the 2004 2.5 CRD has a water cooled EGR valve as is found in the newer CRDs

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2002 Export CRD 2.5 Sport