To cap a fuel rail on a CR you need a 19mm wrench, a tap, and a set screw. (not sure on the size of the tap or set screw)

Here is the pressure relief valve and banjo bolt on a 06 in the truck



Here is the pressure relief valve on a 05 out of the truck



Here is the banjo bolt



Remove out the banjo bolt



Tap the banjo bolt



Put set screw in the banjo bolt



Reinstall banjo bolt



Now your relief valve can blow off but no pressure can get out. **CAUTION** Doing this can cause harm to the fuel system. This relief was installed by Chrysler for a reason, keep that in mind.

 

Awesome! Thanks for the write up, I'm proably gonna wait on this mod till I get a rail pressure gauge installed so I know exactly what is going on! Whats the highest "safe pressure to run at? 27,500ish?

 

it might be hard to hold that kind of pressure with some aggressive tuning

But 27kpsi what i run

 

Alright, I got the Rail pressure gauge in my truck to day and at WOT I can get about 24,000ish +/- Is that normal sounding with the mods I have? Plus when I floor it, it'll get around 15,000 and it will drop 1 to 2k then scream up to 24k ish, it does it every time. Normal? I'll try to get a vid of it when I get some free time.... Side note though Di-Pricol gauges are some awesome lookin and the quality is second to none! Nice stuff.....

 

thats a good pressure, what kind of tune are u running

 

90 hp tune on both the Smarty and on the Banks Six Gun. Thats all the clutch is willing to take at the moment

 

I honestly have not really looked at mine lately, but I am fairly sure I have seen in excess of 26K a few times.

 

well thats good enough, if only there were a way to see commanded RP.

too bad u dont have efi. But if it goes any lower u can mod ur FCA to maintain higher RP. A bigger tune should demmand the same ammount of RP if not more, if u notce that it is not as high with a bigger tune time for some fuel upgrades to get more psi

 

Went out and played alil to day and I was in fifth matted and got'er wound up to 3350 and the rail pressure was pegged to 28K

 

very helpful thread!

1/8" NPT tap and plug. But I recomend just getting a real cap. You've now got 25000psi of diesel trying to cut between the banjo bolt threads and the relief valve housing, and that top sealing washer having to hold it back. Neither were designed to do so. I always had a little weep around my banjo bolt untill I just got the real cap.