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SM 30

This document outlines the standard procedures for handling diesel fuel system contamination in Chrysler 300 vehicles, detailing steps for both scenarios where the engine was started or not after using incorrect fuel. It includes instructions for draining the fuel tank, replacing filters, and checking for contaminants in the fuel system. Additionally, it provides specifications for fuel system pressure and torque values for various components, as well as descriptions of different types of quick-connect fittings used in the fuel system.

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0% found this document useful (0 votes)

31 views321 pages

SM 30

Uploaded by

jonas

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ENGINE

Fuel System - Chrysler 300

FUEL DELIVERY, DIESEL

STANDARD PROCEDURE

DIESEL FUEL SYSTEM CONTAMINATION

NOTE: Fuel system damage that was caused by incorrect or contaminated fuel that
was introduced into the fuel system by the customer is not covered under
warranty.

IF THE ENGINE WAS NOT STARTED AFTER INCORRECT OR CONTAMINATED FUEL WAS USED DURING
REFUELING

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If the fuel system has been contaminated (with gasoline, water, etc.) AND the engine WAS NOT
STARTED, the following procedure must be followed:

1. Drain the fuel from the fuel tank. Refer to DRAINING FUEL TANK - DIESEL . 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.

IF THE ENGINE WAS STARTED AFTER INCORRECT OR CONTAMINATED FUEL WAS USED DURING REFUELING

If the fuel system has been contaminated (with gasoline, water, etc.) AND the engine WAS
STARTED, the following procedure must be followed:

1. Remove all fuel from the fuel tank. Refer to DRAINING FUEL TANK - DIESEL . 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 the fuel tank. Refer to TANK, FUEL, REMOVAL or TANK, FUEL, REMOVAL.
3. Ensure the swirl pot indentation below the in the fuel tank electric fuel pump inlet is completely
drained of any contaminated fuel.
4. Completely drain the low pressure fuel lines, and install a new fuel filter.
5. Install the fuel tank, and fill with clean diesel fuel.
6. Lift up on locking retaining tab to unlock the lock the fuel injector return line from injector
7. Disconnect the low pressure fuel injector return line T-Fitting from fuel injector.
8. Connect a clean hose to the T-Fitting orifice, and place the other end in a suitable clean
container.
9. Turn the ignition ON, and collect the fuel escaping from the T-Fitting orifice in a clean container.
Check the fuel sample for metal chips, dirt, or other foreign matter.
10. If any dirt or metal chips are present in the fuel sample, completely clean the high pressure side
of the fuel injection system, then install new the fuel injectors, and the high pressure fuel pump.
11. If there are no metal chips or dirt present in the fuel sample, the fuel system is OK. Reconnect
the T-Fitting orifice, and road test the vehicle to verify normal operation.

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DRAINING FUEL TANK - DIESEL

CONVENTIONAL PROCEDURE

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. Disconnect the fuel supply line at the quick-connect fitting. Refer to STANDARD
PROCEDURE .
2. Install the appropriate Fuel Line Adapters / Fitting from the (special tool #8978A, Decay Tool,
Fuel). Route the opposite end of this hose to an diesel fuel draining station.

NOTE: Activation of the fuel pump module may time out and need to be restarted
several times to completely drain the fuel tank.

3. Using a diagnostic scan tool, activate the fuel pump module until the fuel tank has been
evacuated.

ALTERNATIVE PROCEDURE

NOTE: If the electric fuel pump is not operating, the fuel tank must be removed and
drained through the fuel pump module opening of the fuel tank.

1. Disconnect the negative battery cable.

2. Remove fuel pump module. Refer to MODULE, FUEL PUMP, REMOVAL or MODULE, FUEL
PUMP, REMOVAL.
3. After fuel pump module has been removed, drain fuel into an approved diesel fuel oil draining
station.
SPECIFICATIONS

TORQUE

DESCRIPTION N.m Ft. Lbs. In. Lbs.

Fuel Filter Cap 20 - 177
Fuel Filter/Water
20 - 177
Separator Bracket Nuts
Fuel Filler Tube Nut 12 - 106
Fuel Heater/Temperature
10 - 89
Sensor Bolts
Fuel Injection Pump
25 18 -
Cover Bolts
Fuel Injection Pump Gear
80 59 -
Nut

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Fuel Injection Pump Bolts 25 18 -
Fuel Rail Bolt 25 18 -
Fuel Tank Strap Bolts 27 20 -
Fuel Tube Union Nut at
11 + 75° - 97 + 75°
Fuel Injector
Fuel Tube Union Nut at
5 + 75° - 44 + 75°
Fuel Rail
High Pressure Crossover
5 + 75° - 44 + 75°
Fuel Tube Union Nut
High Pressure Pump Fuel
Tube Union Nut at Fuel 5 + 75° - 44 + 75°
Rail
High Pressure Pump Fuel 11 + 75° - 97 + 75°
Tube Union Nut at High
Pressure Pump
High Pressure Fuel Tube
11 - 97
support Bracket Bolt
High Pressure Fuel Tube
11 - 97
Support Bracket Nut

FUEL SYSTEM PRESSURE - DIESEL

The correct fuel pressure from the in-tank electric fuel pump to the high pressure injection pump for
this vehicle is 59 psi +/- 2 psi. The correct flow rate for the in-tank electric fuel pump is approximately
53 gph (200 lph) at an ambient temperature of 73° F (23° C) and a constant battery voltage of 13
volts DC.

SPECIAL TOOLS

SPECIAL TOOLS
8978A - Decay Tool, Fuel
9340 - SAE Fuel Pump Lock Ring Wrench
(Originally Shipped In Kit Number(s) 9327, 9327CC, 9397, 9575.)
VM.10339 - Tool, Crankshaft Timing
VM.10344 - Tool, Oil Separator Remover/Installer
VM.10345 - Tool, High Pressure Pump Installation

FILTER, FUEL

REMOVAL

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Fig. 1: Drain Plug & Filter Cover
Courtesy of CHRYSLER GROUP, LLC

1. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .

2. Loosen drain plug (2) and drain fuel filter/water separator into a suitable container.
3. Securely tighten drain plug (2).
4. Remove each filter cover (1) and the fuel filter.
Fig. 2: Fuel Filter Cover & Fuel Filter

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Courtesy of CHRYSLER GROUP, LLC

5. While holding the fuel filter cover (3), pull up on fuel filter (2) to separate from cover (3).

INSTALLATION

Fig. 3: New O-Ring Seal & Filter Covers

Courtesy of CHRYSLER GROUP, LLC

1. Lubricate and install a new O-ring seal (2) onto filter covers (1).
Fig. 4: Fuel Filter Cover & Fuel Filter

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Courtesy of CHRYSLER GROUP, LLC

2. Position and push down on new fuel filters (2) to install filter onto cover (3).
3. Lubricate the rubber grommet seal (1) with clean diesel fluid.

Fig. 5: Drain Plug & Filter Cover

Courtesy of CHRYSLER GROUP, LLC

4. Install the fuel filters. Tighten each cover (1) to 20 N.m (177 in. lbs.).
5. Lower the vehicle.
6. Start the vehicle and inspect for leaks.

FITTING, QUICK CONNECT

DESCRIPTION
DESCRIPTION

Different types of quick-connect fittings are used to attach the various fuel system components, lines
and tubes. These are: a single-button type shown in illustration above. a two-button type, a pinch
type, a single-tab type, a two-tab type or a plastic retainer ring type. Some are equipped with safety
latch clips. Some may require the use of a special tool for disconnection and removal. Refer to
QUICK-CONNECT FITTINGS for more information.

CAUTION: Before separating a Quick-Connect fitting, pay attention to what type of

fitting is being used. Refer to QUICK-CONNECT FITTINGS . This will
prevent unnecessary fitting or fitting latch breakage.

CAUTION: The interior components (O-rings, clips and latches) of Quick-Connect

fittings are not serviced separately, but new plastic spacers and latches
are available for some types. If service parts are not available, do not
attempt to repair the damaged fitting or fuel line (tube). If repair is

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necessary, replace the complete fuel line (tube) assembly.

STANDARD PROCEDURE

QUICK-CONNECT FITTINGS

Different types of quick-connect fittings are used to attach the various fuel system components, lines
and tubes. These are: a single-button type, a two-button type, a pinch type, a single-tab type, a two-
tab type or a plastic retainer ring type. Some are equipped with safety latch clips. Some may require
the use of a special tool for disconnection and removal.

These are the quick-connect fittings:

Redundant Latch Single Button Type Fitting

Single Button Type Fitting
Pinch Type Fitting
Single Tab Type Fitting
Two Tab Type Fitting
Plastic Retainer Ring Type Fitting
Latch Clip Type 1 Fitting
Latch Clip Type 2 Fitting
Wing Type Fitting

DISCONNECTING

CAUTION: Before separating a Quick-Connect fitting, pay attention to what type of

fitting is being used. This will prevent unnecessary fitting or fitting latch
breakage.
CAUTION: The interior components (O-rings, clips) of quick-connect fittings are not
serviced separately, but new plastic spacers and latches are available for
some types. If service parts are not available, do not attempt to repair the
damaged fitting or fuel line (tube). If repair is necessary, replace the
complete fuel line (tube) assembly.

REDUNDANT LATCH SINGLE BUTTON TYPE FITTING:

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Fig. 6: Redundant Latch & Push Button
Courtesy of CHRYSLER GROUP, LLC

This type of quick-connect fitting is equipped with a redundant latch (2) and a single push button (1)
that releases two internal latches located in the quick-connect fitting. Special tools are not required for
removal.

Fig. 7: Redundant Latch & Internal Latches

Courtesy of CHRYSLER GROUP, LLC

CAUTION: Do not pry or pull up on the push button as damage to the latches of the
quick-connect fitting will occur.

1. Pull the redundant latch (2) out away from the quick-connect fitting.
2. Press on the push button with your thumb, release the internal latches (1) and remove the
quick-connect fitting from the fuel system component.

SINGLE BUTTON TYPE FITTING:

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Fig. 8: Single Button Fitting
Courtesy of CHRYSLER GROUP, LLC

CAUTION: Do not pry or pull up on the push button as damage to the latches of the
quick-connect fitting will occur.

This type of quick-connect fitting is equipped with a single push button (2) that releases two internal
latches located in the quick-connect fitting. Special tools are not required for removal.
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Fig. 9: Ouick-Connect Fitting Latches
Courtesy of CHRYSLER GROUP, LLC

1. Press on the push button with your thumb, release the internal latches (1).
2. Remove the quick-connect fitting from the fuel system component.

2 BUTTON TYPE FITTING

Fig. 10: View Of 2-Button Type Fitting

Courtesy of CHRYSLER GROUP, LLC
This type of quick-connect fitting (1) is equipped with two push buttons (2) that releases two internal
latches located in the quick-connect fitting. Special tools are not required for removal.

1. Press on both push buttons with your thumb, release the internal latches.
2. While holding the two push buttons simultaneously, remove the quick-connect fitting from the
fuel system component.

PINCH TYPE FITTING

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Fig. 11: View Of Pinch Type Quick-Connect Fitting
Courtesy of CHRYSLER GROUP, LLC

This type of quick-connect fitting (1) is equipped with two finger tabs (2). Special tools are not
required for removal.

1. Pinch both tabs (2) together and release the quick-connect fitting.
2. Remove the quick-connect fitting from the fuel system component.

SINGLE TAB TYPE FITTING

Fig. 12: View Of Single-Tab Type Fitting
Courtesy of CHRYSLER GROUP, LLC

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This type of quick-connect fitting (3) is equipped with a single pull tab (1). The tab is removable. After
tab is removed the quick-connect fitting can be separated from the fuel system component. Special
tools are not required for removal.

Fig. 13: Disconnecting Single-Tab Type Fitting

Courtesy of CHRYSLER GROUP, LLC

1. Press release tab on side of fitting to release pull tab (1). If release tab is not pressed prior to
releasing pull tab, pull tab will be damaged.
2. While pressing the release tab on the side of the quick-connect fitting use a screwdriver (2) to
pry up the pull tab.
3. Raise the pull tab until it separates from the quick-connect fitting.
4. Remove the quick-connect fitting from the fuel system component.
TWO TAB TYPE FITTING

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Fig. 14: Identifying Typical 2-Tab Type Fitting
Courtesy of CHRYSLER GROUP, LLC

This type of quick-connect fitting (2) is equipped with tabs located on both sides of the fitting (1).
These tabs are integral to the fuel system component. The plastic tabs will remain on the component
being serviced after the quick-connect fitting is removed. The O-ring and spacer will remain in the
quick-connect fitting. Special tools are not required for removal.

1. Squeeze the plastic tabs (1) against the sides of component being serviced with your fingers.
2. Remove the quick-connect fitting from the fuel system component.

PLASTIC RETAINER RING TYPE FITTING

Fig. 15: Plastic Retainer Ring Type Fitting

Courtesy of CHRYSLER GROUP, LLC
This type of fitting can be identified by the use of a round plastic retainer ring (4) usually black in
color. Special tools are not required for removal.

NOTE: The round plastic retainer ring must be pressed squarely into the quick-connect
fitting body. If this retainer is cocked during removal it will be difficult to
disconnect the quick-connect fitting. Use an open-end wrench on the shoulder
of the plastic retainer ring to aid in disconnection.

1. Firmly push the quick-connect fitting (5) towards the component being serviced while firmly
pushing the round plastic retainer ring into the quick-connect fitting (6). With the round plastic
ring depressed, remove the quick-connect fitting from the fuel system component.
2. After removal the plastic retainer ring will remain with the quick-connect fitting.

LATCH CLIP TYPE 1 FITTING

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Fig. 16: Tethered, Latch Clip & Screwdriver
Courtesy of CHRYSLER GROUP, LLC

Depending on vehicle model and engine, 2 different types of safety latch clips are used. One is
tethered (1) to fuel line and the other is not. A special tool will be necessary to disconnect the fuel line
after latch clip is removed. The latch clip may be used on certain fuel line and fuel rail connections or
to join fuel lines together.

1. Pry up on the latch clip (4) with a screwdriver (3).

2. Slide the latch clip away from the quick-connect fitting while lifting the screwdriver and position
aside.
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Fig. 17: Fuel Line Disconnection Using Special Tool
Courtesy of CHRYSLER GROUP, LLC

3. Insert the commercially available fuel line removal tool (1) into the quick-connect fitting and
release the internal latches.

NOTE: After removal the internal latches will remain in the quick-connect fitting.

4. With the commercially available fuel line removal tool (1) still inserted, remove the quick-connect
fitting from the fuel system component.

LATCH CLIP TYPE 2 FITTING

Fig. 18: Latch Clip

Courtesy of CHRYSLER GROUP, LLC

Depending on vehicle model and engine, 2 different types of safety latch clips are used. One is
tethered to the fuel line and the other is not. A special tool will be necessary to disconnect the fuel line
after the latch clip is removed. The latch clip may be used on certain fuel line and fuel rail connections
or to join fuel lines together.

1. Unlatch the small arms on the end of clip, swing away and separate from the fuel system
component.
2. Slide the latch clip away from the quick-connect fitting while lifting with a screwdriver and
position aside.

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Fig. 19: Fuel Line Disconnection Using Special Tool
Courtesy of CHRYSLER GROUP, LLC

3. Insert the commercially available fuel line removal tool (1) into the quick-connect fitting and
release the internal latches.

NOTE: After removal the internal latches will remain in the quick-connect fitting.

4. With the commercially available fuel line removal tool (1) inserted, remove the quick-connect
fitting from the fuel system component.

WING TYPE FITTING

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Fig. 20: EVAP Can. Vapor Hose
Courtesy of CHRYSLER GROUP, LLC

The wing type fitting is used on fuel system and emission components. The wing type fitting is most
commonly used on the EVAP canister (3). Special tools are not required for removal.

1. Using two fingers, press both wings (2) and release the locking tabs.

NOTE: After removal the locking tabs will remain with the quick-connect fitting.

2. While holding the wings, remove the quick-connect fitting from the fuel system component.

CONNECTING

1. Inspect the quick-connect fitting body and fuel system components for damage. Replace as
necessary.
2. Prior to connecting any quick-connect fitting to components, check condition of fitting and
components. Clean parts with a lint-free cloth. Lubricate with clean engine oil.
3. Insert the quick-connect fitting onto the fuel tube or fuel system component until the built-in stop
on the fuel tube or component rests against the back of fitting.
4. Continue pushing until a click is felt.
5. If Equipped:
Redundant Latch Single Button Type Fitting: Push redundant latch until it locks into
position in the quick-connect fitting.
Single Tab Type Fitting: Push new tab down until it locks into position in the quick-
connect fitting.
Latch Clip Type Fitting: Install latch clip (snaps into position). If latch clip will not snap
into position, this indicates the quick-connect fitting is not properly installed onto
fuel system component, recheck the connection.
6. Verify a locked condition by firmly pulling on the quick-connect fitting connection of the fuel
system component.

HEATER, FUEL

REMOVAL

1. Disconnect the negative battery cable.

2. Remove the fuel filter/water separator assembly. Refer to SEPARATOR AND FILTER, FUEL
AND WATER, REMOVAL.

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Fig. 21: Bolts & Fuel Heater/Temperature Sensor
Courtesy of CHRYSLER GROUP, LLC

3. Remove bolts (2), and the fuel heater/temperature sensor (1).

4. Remove and discard O-ring seal.

INSTALLATION

INSTALLATION
Fig. 22: Bolts & Fuel Heater/Temperature Sensor

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Courtesy of CHRYSLER GROUP, LLC

1. Clean the O-ring surface sealing area.

NOTE: Lubricate the O-ring seal with clean diesel fluid.

2. Using a new O-ring seal, install the fuel heater/temperature sensor (1). Tighten bolts (2) to 10
N.m (89 in. lbs.).
3. Install the fuel filter/water separator assembly. Refer to SEPARATOR AND FILTER, FUEL
AND WATER, INSTALLATION.
4. Connect the negative battery cable.

MODULE, FUEL PUMP

REMOVAL

MAIN FUEL PUMP MODULE

WARNING: The fuel system is under constant high pressure even with engine off.
Until the fuel pressure has been properly released from the system, do
not attempt to open the fuel system. Do not smoke or use open
flames/sparks when servicing the fuel system. Wear protective clothing
and eye protection. Make sure the area in which the vehicle is being
serviced is in a well ventilated area and free of flames/sparks. Failure to
comply may result in serious or fatal injury.

CAUTION: If the electric fuel pump module is not operating or the fuel level sending
unit is not operating and the fuel level cannot be determined, the fuel tank
must be removed prior to draining. If the fuel level is above 5/8 of a tank
and the fuel pump module lock-ring is removed, fuel will spill into the
interior of the vehicle

1. Verify the fuel level is below 5/8 of a tank.

2. If required, perform the draining fuel tank procedure. Refer to DRAINING FUEL TANK .
3. Disconnect the negative battery cable.

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Fig. 23: Pulling Rear Seat Up
Courtesy of CHRYSLER GROUP, LLC

4. Push the rear lower seat cushion up and back and remove the seat cushion.
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Fig. 24: Foam Pad Under Seat
Courtesy of CHRYSLER GROUP, LLC

5. Fold back the foam pad covering the fuel pump module plastic access covers.

Fig. 25: Mastic Sound Deadener & Left Side Main Fuel Pump Module Plastic Access
Cover
Courtesy of CHRYSLER GROUP, LLC

6. Using a razor knife, cut the mastic sound deadener as shown in illustration (1).
7. Remove the left side main fuel pump module plastic access cover (2).
Fig. 26: Left Side Module Orientation

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Courtesy of CHRYSLER GROUP, LLC

8. Disconnect the electrical connector from the main fuel pump module.

CAUTION: An indexing arrow is located on top of the fuel pump module to clock
it's position into the fuel tank, note it's location for reassembly.

Fig. 27: Left Side Module

Courtesy of CHRYSLER GROUP, LLC

NOTE: Prior to removing the fuel pump module, use compressed air to remove
any accumulated dirt and debris from around fuel tank opening.

9. Mark the main fuel pump module orientation.

10. Position the (special tool #9340, SAE Fuel Pump Lock Ring Wrench) (1) into the notches on the
outside edge of the lock ring.
11. Install a 1/2 inch drive breaker bar into the (special tool #9340, SAE Fuel Pump Lock Ring
Wrench) (1).

NOTE: The main fuel pump module will spring up slightly when the lock ring is
removed.

12. Rotate the breaker bar counterclockwise and remove the lock ring.

CAUTION: Do not allow the float arm of the Main Fuel Pump Module to come in
contact with any part of the fuel tank during removal or installation,
damage to the float arm and fuel level sending card may result.

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Fig. 28: Module Electrical Connectors
Courtesy of CHRYSLER GROUP, LLC

13. Raise and separate the top section from the bottom section of the main fuel pump module.
14. Disconnect the electrical connectors from under the top section of the main fuel pump module.
15. Remove the top section of the main fuel pump module from the vehicle.
Fig. 29: Line Release

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Courtesy of CHRYSLER GROUP, LLC

16. Press the quick connect release tab (3) and remove the fuel supply line (1) from the main fuel
pump module.

Fig. 30: Hose Connections Drivers Side

Courtesy of CHRYSLER GROUP, LLC

17. Disconnect the fuel return lines (1, 2) from the main fuel pump module.

NOTE: Do not spill fuel into the interior of the vehicle.

18. Carefully lift the bottom section of the main fuel pump module out of the fuel tank, tip the bottom
section on its side and drain the remaining fuel from the bottom reservoir into the fuel tank and
remove from vehicle.

NOTE: Whenever a fuel pump module is serviced, the rubber O-ring seal must be
replaced.

19. Remove and discard the rubber O-ring seal.

AUXILIARY FUEL PUMP MODULE

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Fig. 31: Mastic Sound Deadener & Auxiliary Fuel Pump Module Plastic Access Cover
Courtesy of CHRYSLER GROUP, LLC

NOTE: The Main Fuel Pump Module must be removed for Auxiliary Fuel Pump Module
removal.

1. Remove the main fuel pump module. Refer to MAIN FUEL PUMP MODULE.
2. Using a razor knife, cut the mastic sound deadener as shown in illustration (1).
3. Remove the auxiliary fuel pump module plastic access cover (2) from the floor pan.
Fig. 32: Right Side Module Orientation

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Courtesy of CHRYSLER GROUP, LLC

NOTE: Prior to removing the fuel pump module, use compressed air to remove
any accumulated dirt and debris from around fuel tank opening.

4. Disconnect the fuel supply line (2) from the auxiliary fuel pump module (1).
5. Mark the auxiliary fuel pump module orientation.

Fig. 33: Right Side Module

Courtesy of CHRYSLER GROUP, LLC

6. Position the (special tool #9340, SAE Fuel Pump Lock Ring Wrench) (1) into the notches on the
outside edge of the lock ring (2).
7. Install a 1/2 inch drive breaker bar into the (special tool #9340, SAE Fuel Pump Lock Ring
Wrench) (1).
8. Rotate the breaker bar counterclockwise and remove the lock ring (2).

CAUTION: Do not allow the float arm of the Auxiliary Fuel Pump Module to come
in contact with any part of the fuel tank during removal or
installation, damage to the float arm and fuel level sending card may
result.

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Fig. 34: Remove/Install Right Side Module
Courtesy of CHRYSLER GROUP, LLC

9. Lift the auxiliary fuel pump module up and out of fuel tank while guiding the fuel supply and
return lines out from the left side of the fuel tank.

NOTE: Whenever a fuel pump module is serviced, the rubber O-ring seal must be
replaced.

10. Remove and discard the rubber O-ring seal.

INSTALLATION

MAIN FUEL PUMP MODULE

WARNING: No sparks, open flames or smoking. Risk of poisoning from inhaling and
swallowing fuel. Pour fuel only into appropriately marked OSHA approved
containers. Wear protective clothing. Risk of injury to eyes and skin from
contact with fuel.
CAUTION: Do not allow the float arm of the Main Fuel Pump Module to come in
contact with any part of the fuel tank during removal or installation,
damage to the float arm and fuel level sending card may result.

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Fig. 35: Hose Connections Drivers Side
Courtesy of CHRYSLER GROUP, LLC

NOTE: The Auxiliary Fuel Pump Module must be installed before the Main Fuel Pump
Module.

1. If the auxiliary fuel pump module is removed. Refer to AUXILIARY FUEL PUMP MODULE.

NOTE: Whenever the fuel pump module is serviced, the rubber O-ring seal must
be replaced.

2. Install a new rubber O-ring seal.

3. Using caution not to bend the float arm, lower the bottom section of the main fuel pump module
into the fuel tank.
4. Connect the fuel return lines (1, 2) to the main fuel pump module.
Fig. 36: Line Release

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Courtesy of CHRYSLER GROUP, LLC

5. Connect the fuel supply line (1) to the main fuel pump module.

Fig. 37: Module Electrical Connectors

Courtesy of CHRYSLER GROUP, LLC

6. Connect the electrical connectors at the top section of the main fuel pump module.
7. Join the upper section and lower section of the main fuel pump module together.
8. Position the main fuel pump module as noted during removal.

CAUTION: Verify the electrical wires are tucked away into the fuel tank so they
don't get pinched between the top of the fuel pump module and the
rubber O-ring seal.

CAUTION: An indexing arrow is located on top of the fuel pump module to clock
it's position into the fuel tank. The fuel pump module must be
installed in the same position as removed.

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Fig. 38: Left Side Module Orientation
Courtesy of CHRYSLER GROUP, LLC

9. Align the rubber O-ring seal and lower the main fuel pump module into position.
10. Verify the main fuel pump module is in the same position as noted during removal. This step
must be performed to prevent the float from contacting the side of the fuel tank.

Fig. 39: Left Side Module

Courtesy of CHRYSLER GROUP, LLC
11. Position the lock ring over top of the main fuel pump module.
12. Position the (special tool #9340, SAE Fuel Pump Lock Ring Wrench) (1) into the notches on the
outside edge of the lock ring.
13. Install a 1/2 inch drive breaker bar into the (special tool #9340, SAE Fuel Pump Lock Ring
Wrench).
14. Rotate the breaker bar clockwise until all seven notches of the lock ring have engaged.

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Fig. 40: Left Side Module Orientation
Courtesy of CHRYSLER GROUP, LLC

15. Connect the electrical connector (1) to the main fuel pump module.
16. Fill the fuel tank and check for leaks around the rubber O-ring seal.

Fig. 41: Mastic Sound Deadener & Left Side Main Fuel Pump Module Plastic Access
Cover
Courtesy of CHRYSLER GROUP, LLC
17. Install the main fuel pump module plastic access cover (2).

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Fig. 42: Foam Pad Under Seat
Courtesy of CHRYSLER GROUP, LLC

18. Lower the foam pad covering back into place.

Fig. 43: Pulling Rear Seat Up

Courtesy of CHRYSLER GROUP, LLC

19. Push the rear lower seat cushion back and down and install the seat cushion.
20. Connect the negative battery cable.

AUXILIARY FUEL PUMP MODULE

CAUTION: An indexing arrow is located on top of the fuel pump module to clock it's
position into the fuel tank. The fuel pump module must be installed in the
same position as removed.

CAUTION: Do not allow the float arm of the Auxiliary Fuel Pump Module to come in
contact with any part of the fuel tank during removal or installation,
damage to the float arm and fuel level sending card may result.

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Fig. 44: Remove/Install Right Side Module
Courtesy of CHRYSLER GROUP, LLC

NOTE: Whenever the fuel pump module is serviced, the rubber O-ring seal must be
replaced.

1. Install a new rubber O-ring seal.

2. Using caution not to bend the float arm, lower the auxiliary fuel pump module into the fuel tank
while guiding the fuel return lines, fuel supply line and electrical connector over to the left side of
the fuel tank.
3. Align the rubber O-ring seal and lower the auxiliary fuel pump module into position as noted
during removal.
4. Position the lock ring over top of the auxiliary fuel pump module.
5. Verify the auxiliary fuel pump module is in the same position as noted during removal. This step
must be performed to prevent the float from contacting the side of the fuel tank.
Fig. 45: Right Side Module

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Courtesy of CHRYSLER GROUP, LLC

6. Position (special tool #9340, SAE Fuel Pump Lock Ring Wrench) (1) into the notches on the
outside edge of the lock ring (2).
7. Install a 1/2 inch drive breaker bar into the (special tool #9340, SAE Fuel Pump Lock Ring
Wrench) (1).
8. Rotate the breaker bar clockwise until all seven notches of the lock ring have engaged.

Fig. 46: Right Side Module Orientation

Courtesy of CHRYSLER GROUP, LLC

9. Connect the fuel supply line (2) to auxiliary fuel pump module (1).
Fig. 47: Mastic Sound Deadener & Auxiliary Fuel Pump Module Plastic Access Cover

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Courtesy of CHRYSLER GROUP, LLC

10. Install the auxiliary fuel pump module plastic access cover (1).
11. Install the main fuel pump module. Refer to MAIN FUEL PUMP MODULE.

PUMP, FUEL INJECTION, HIGH PRESSURE

DESCRIPTION

WARNING: High pressure fuel lines deliver diesel fuel under extreme pressure from
the injection pump to the fuel injectors. This may be as high as 1800 bar
(26, 106 psi). Use extreme caution when inspecting for high pressure fuel
leaks. Fuel under this amount of pressure can penetrate skin causing
personal injury or death. Inspect for high pressure fuel leaks with a sheet
of cardboard. Wear safety goggles and adequate protective clothing when
servicing fuel system.
Fig. 48: High Pressure Pump, Gear & Nut

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Courtesy of CHRYSLER GROUP, LLC

The high pressure pump (3) is mounted to the left rear of the cylinder head and there is a protection
blocker plate attached to the front of the high pressure pump. The only serviceable part on the high
pressure pump is the fuel quantity solenoid, the drive gear, and the O-ring seal. The high pressure
pump must not be disassembled or opened. The high pressure pump has a screen filter that is not
serviceable. If diagnosis has led you to believe that the filter is restricted of plugging up then the high
pressure pump needs to be replaced.

OPERATION

CAUTION: Cranking the engine for an extended time without a fuel supply may
damage the fuel injection pressure pump.

The High Pressure Delivery Pump (HPDP) supplies pressurized fuel between 200-1800 bar (2, 900 -
26, 106 psi) to the fuel rail and fuel injectors. The cascade valve, located inside the HPDP regulates
the pressure in the low side and diverts some of the fuel entering for lubrication of the pump. The
Powertrain Control Module (PCM) monitors high side fuel pressure via a fuel pressure sensor. Based
on readings from the fuel pressure sensor, the PCM controls the output pressure of the pump using
the Fuel Quantity Solenoid (FQS), which mounts to the HPDP.
NOTE: The high pressure pump must not be disassembled or opened. The only
serviceable items are the fuel quantity solenoid, the pump gear, and the O-ring
seal.

REMOVAL

WARNING: High-pressure fuel lines deliver fuel under extreme pressure from the
injection pump to the injectors. This maybe as high as 1800 bar (26, 106
psi). Use extreme caution when inspecting for high-pressure fuel leaks.
Inspect high-pressure fuel leaks with a sheet of cardboard. Wear safety
goggles and adequate protective clothing when servicing fuel system.
Fuel under this amount of pressure can penetrate skin causing serious or
fatal injury.

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Fig. 49: Engine Cover
Courtesy of CHRYSLER GROUP, LLC

1. Disconnect the negative battery cable.

2. Remove engine cover (1).
Fig. 50: CCV Hose

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3. Disconnect the CCV hose (1) from oil breather/camshaft seal housing.

Fig. 51: Oil Breather/Camshaft Seal Housing, Gasket & Bolt

Courtesy of CHRYSLER GROUP, LLC

4. Remove bolts (1) and the oil breather/camshaft seal housing (2).
5. Remove and discard gasket (3).
Fig. 52: Oil Separator Remover/Installer & Oil Separator

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Courtesy of CHRYSLER GROUP, LLC

6. Using (special tool #VM.10344, Tool, Oil Separator Remover/Installer) (2), remove the oil
separator (1) from the left intake camshaft.

Fig. 53: Holes & Small Dimple

Courtesy of CHRYSLER GROUP, LLC

7. Rotate the engine and observe the location of holes (2) on the camshaft gear and the small
dimple (1). If these marks facing the intake manifold the engine is 180° off time.
8. Lock the engine at 30° ATDC. Refer to STANDARD PROCEDURE ,STANDARD
PROCEDURE , VALVE TIMING &VALVE TIMING .
9. Remove the cowl panel cover. Refer to COVER, COWL PANEL, REMOVAL .
10. Remove bolts and the strut tower support.
Fig. 54: High Pressure Pump Blocker & Bolts

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Courtesy of CHRYSLER GROUP, LLC

11. Remove bolts (2) and the high pressure pump blocker (1).

Fig. 55: Low Pressure Supply & Return

Courtesy of CHRYSLER GROUP, LLC

12. Disconnect the low pressure supply (2) and return (1) lines from high pressure pump (3). Refer
to FITTING, QUICK CONNECT .
Fig. 56: Fuel Quantity Solenoid Wire Harness Connector

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Courtesy of CHRYSLER GROUP, LLC

13. Disconnect the fuel quantity solenoid wire harness connector (3).

Fig. 57: Fuel Tube Securing Bolts & Bracket

Courtesy of CHRYSLER GROUP, LLC

14. Remove the EGR tube. Refer to TUBE, EXHAUST GAS RECIRCULATION (EGR),
REMOVAL .
15. Remove nut (1) securing the fuel tube.
16. Remove bolt (3) securing the fuel tube.
17. Remove bolts (4) and the bracket (2) securing the fuel tubes.
Fig. 58: High Pressure Fuel Crossover Tube, Left High Pressure Fuel Tube & Fasteners

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Courtesy of CHRYSLER GROUP, LLC

18. Loosen union nuts (1, 5) and remove the right high pressure fuel tube (2) and discard fuel tube.
19. Loosen union nuts (6, 9) and remove the left high pressure fuel tube (7) and discard fuel tube.

Fig. 59: Fuel Injection Pump

Courtesy of CHRYSLER GROUP, LLC

20. Remove the three bolts (1) and the high pressure pump (2).
Fig. 60: High Pressure Pump, Gear & Nut

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21. If necessary, remove nut (1) and gear (2) from the high pressure pump (3).

INSTALLATION

CAUTION: Do Not Force the high pressure pump into the right timing cover or
attempt to seat it by drawing it in with the bolts. The pump gear must be
properly aligned with the drive gear on the camshaft before the high
pressure pump will seat on the cylinder head mounting surface. Failure to
properly align drive gears will damage the high pressure pump or
camshaft drive gear.
Fig. 61: High Pressure Pump, Gear & Nut

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Courtesy of CHRYSLER GROUP, LLC

1. If removed, install the gear (2) and nut (1) onto the high pressure pump (3). Tighten nut (1) to 80
N.m (59 ft. lbs.).

Fig. 62: Fuel Quantity Solenoid

Courtesy of CHRYSLER GROUP, LLC

2. Mark the center line on the fuel quantity solenoid (1) with a paint pan as making a reference to
zero 0°.
Fig. 63: Hole On The Gear & Reference Mark

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3. Using a paint pen, mark the gear and the hole as a reference mark.
4. Rotate the pump shaft so the paint mark and hole on the gear (1) aligns with the 0° reference
mark (2) on pump.

Fig. 64: Degree Wheel To Zero & Fuel Quantity Solenoid

Courtesy of CHRYSLER GROUP, LLC

5. Align the commercially available degree wheel to zero (2) with the center line on fuel quantity
solenoid (1).
Fig. 65: Index Mark

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Courtesy of CHRYSLER GROUP, LLC

6. Rotate the pump gear clockwise so the index mark (1) on drive gear aligns at the 65° mark on
the degree wheel (2).

Fig. 66: High Pressure Pump & O-Ring

Courtesy of CHRYSLER GROUP, LLC

7. Install a new O-ring seal (1) onto the high pressure pump (2).
Fig. 67: Pump Installer Tool & Timing Cover

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Courtesy of CHRYSLER GROUP, LLC

8. Install the (special tool #VM.10345, Tool, High Pressure Pump Installation) (2) into the rear
cover (1).
9. Position the high pressure pump onto the (special tool #VM.10345, Tool, High Pressure Pump
Installation) and install the high pressure pump.
10. Remove the (special tool #VM.10345, Tool, High Pressure Pump Installation) (2).

Fig. 68: Fuel Injection Pump

Courtesy of CHRYSLER GROUP, LLC

11. Install the three high pressure pump bolts (1) and tighten to 25 N.m (18 ft. lbs.).
Fig. 69: High Pressure Fuel Crossover Tube, Left High Pressure Fuel Tube & Fasteners

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Courtesy of CHRYSLER GROUP, LLC

NOTE: Fuel tubes are a one time only use and must be replaced anytime they
have been removed.

12. Install the new left high pressure fuel tube (7) and tighten union nuts (6, 9) finger tight.
13. Install the new right high pressure fuel tube (2) and tighten union nuts (1, 5) finger tight.

Fig. 70: Fuel Tube Securing Bolts & Bracket

Courtesy of CHRYSLER GROUP, LLC

14. Install the bracket (2) securing the fuel tubes. Tighten bolts (4) to 11 N.m (97 in. lbs.).
15. Install bolt (3) securing the right fuel tube and tighten to 11 N.m (97 in. lbs.).
16. Install nut (1) securing the left fuel tube and tighten to 11 N.m (97 in. lbs.).
17. Install the EGR tube. Refer to TUBE, EXHAUST GAS RECIRCULATION (EGR),
INSTALLATION .

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Fig. 71: High Pressure Fuel Crossover Tube, Left High Pressure Fuel Tube & Fasteners
Courtesy of CHRYSLER GROUP, LLC

18. Tighten the union nuts as follows:

Tighten union nut (1 and 9) to 5 N.m (44 in. lbs.) plus an additional 75 degrees turn.
Tighten union nut (5 and 6) to 11 N.m (97 in. lbs.) plus an additional 75 degrees turn.

Fig. 72: Fuel Quantity Solenoid Wire Harness Connector

Courtesy of CHRYSLER GROUP, LLC

19. Connect the fuel quantity solenoid harness connector (3).

Fig. 73: Low Pressure Supply & Return

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Courtesy of CHRYSLER GROUP, LLC

20. Connect the low pressure supply (2) and return (1) lines to the high pressure pump.

Fig. 74: High Pressure Pump Blocker & Bolts

Courtesy of CHRYSLER GROUP, LLC

21. Install the fuel pump blocker (1). Tighten bolts (2) to 25 N.m (18 ft. lbs.).
Fig. 75: Crankshaft Timing Tool

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22. Remove (special tool #VM.10339, Tool, Crankshaft Timing) (1).

Fig. 76: Engine Block Plug

Courtesy of CHRYSLER GROUP, LLC

23. Install the engine block plug (1) and tighten 30 N.m (22 ft. lbs.).
24. Install the strut tower support and securely tighten bolts.
25. Install the cowl panel cover. Refer to COVER, COWL PANEL, INSTALLATION .
Fig. 77: Oil Separator Remover/Installer & Oil Separator

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Courtesy of CHRYSLER GROUP, LLC

26. Using the (special tool #VM.10344, Tool, Oil Separator Remover/Installer) (2) Install the oil
separator (1) and tighten to 30 N.m (22 ft. lbs.).

Fig. 78: Oil Breather/Camshaft Seal Housing, Gasket & Bolt

Courtesy of CHRYSLER GROUP, LLC

27. Using a new gasket (3), install the oil breather/camshaft seal housing (2). Tighten bolts (1) to 14
N.m (124 in. lbs.).
Fig. 79: CCV Hose

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Courtesy of CHRYSLER GROUP, LLC

28. Connect the CCV hose (1) from oil breather/camshaft seal housing.

Fig. 80: Engine Cover

Courtesy of CHRYSLER GROUP, LLC

29. Connect the negative battery cable.

30. Start engine and check for leaks.
31. Install the engine cover (1).

RAIL, FUEL

DESCRIPTION
DESCRIPTION

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Fig. 81: High Pressure Pump
Courtesy of CHRYSLER GROUP, LLC

The high pressure pump supplies diesel fuel to the fuel rail which deliveries high pressure fuel to all
injectors. A fuel rail pressure sensor, fuel rail pressure solenoid, and the return flow line are all
combine to keep the fuel pressure in the fuel rail at the required pressure. The fuel rail is attached to
the cylinder head.

OPERATION

The stored fuel volume inside the rail acts as a damper for pressure fluctuations which result because
of pulsating supply and brief large extractions of fuel during injector firing. The rail primarily influences
the atomization of fuel at the injector nozzle, and the accuracy of injected quantity during injection.

REMOVAL

LEFT FUEL RAIL

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. Disconnect the negative battery cable.

2. Remove the intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL or MANIFOLD,
INTAKE, REMOVAL or MANIFOLD, INTAKE, REMOVAL, 5.7L or MANIFOLD, INTAKE,
REMOVAL .
Fig. 82: Fuel Rail Return Line & Fuel Rail Solenoid Connector

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Courtesy of CHRYSLER GROUP, LLC

3. Disconnect the fuel rail solenoid wire harness connector (1).

4. Disconnect the fuel rail return line (2) and position aside.
5. Remove the left bank high pressure fuel tubes. Refer to TUBE(S), FUEL, REMOVAL.

Fig. 83: Left Fuel Rail & Bolts

Courtesy of CHRYSLER GROUP, LLC

6. Remove bolts (2) and the left fuel rail (1).

RIGHT FUEL RAIL

1. Disconnect the negative battery cable.

2. Remove the intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL or MANIFOLD,
INTAKE, REMOVAL or MANIFOLD, INTAKE, REMOVAL, 5.7L or MANIFOLD, INTAKE,
REMOVAL .

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Fig. 84: Fuel Rail Pressure Sensor Connector
Courtesy of CHRYSLER GROUP, LLC

3. Disconnect the fuel rail pressure sensor wire harness connector (1).

Fig. 85: Right Fuel Rail & Bolts

Courtesy of CHRYSLER GROUP, LLC
4. Remove the right bank high pressure fuel tubes. Refer to TUBE(S), FUEL, REMOVAL.
5. Remove bolts (2) the right fuel rail (1).

INSTALLATION

LEFT FUEL RAIL

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Fig. 86: Left Fuel Rail & Bolts
Courtesy of CHRYSLER GROUP, LLC

1. Install the fuel rail (1). Tighten bolts (2) to 25 N.m (18 ft. lbs.).

NOTE: Fuel tubes must be replaced anytime they are removed.

2. Install the high pressure fuel rail tubes. Refer to TUBE(S), FUEL, INSTALLATION.
Fig. 87: Fuel Rail Return Line & Fuel Rail Solenoid Connector

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Courtesy of CHRYSLER GROUP, LLC

3. Position fuel rail return line (2) and connect to fuel rail.
4. Connect the fuel rail pressure solenoid harness connector (1).
5. Install the intake manifold. Refer to MANIFOLD, INTAKE, INSTALLATION or MANIFOLD,
INTAKE, INSTALLATION or MANIFOLD, INTAKE, INSTALLATION, 5.7L or MANIFOLD,
INTAKE, INSTALLATION .
6. Connect the negative battery cable.
7. Start engine and inspect for leaks.

RIGHT FUEL RAIL

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1. Install the fuel rail (1). Tighten bolts (2) to 25 N.m (18 ft. lbs.).

NOTE: Fuel tubes must be replaced anytime they are removed.

2. Install the high pressure fuel rail tubes. Refer to TUBE(S), FUEL, INSTALLATION.

Fig. 89: Fuel Rail Pressure Sensor Connector

Courtesy of CHRYSLER GROUP, LLC

3. Connect the fuel rail pressure sensor wire harness connector (1).
4. Install the intake manifold. Refer to MANIFOLD, INTAKE, INSTALLATION or MANIFOLD,
INTAKE, INSTALLATION or MANIFOLD, INTAKE, INSTALLATION, 5.7L or MANIFOLD,
INTAKE, INSTALLATION .
5. Connect the negative battery cable.
6. Start the engine and inspect for leaks.

REGULATOR, FUEL PRESSURE

DESCRIPTION

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Fig. 90: Fuel Pressure Regulator
Courtesy of CHRYSLER GROUP, LLC

The fuel pressure regulator (1) is attached to the front of the left fuel rail. The fuel pressure regulator
is not a serviceable item. In the event that the fuel pressure regulator fails, the fuel rail must be
replaced. The fuel pressure regulator controls and maintains constant rail pressure with a control
current transmitted by the Powertrain Control Module (PCM).

OPERATION

OPERATION
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Fig. 91: Fuel Pressure Solenoid Operation
Courtesy of CHRYSLER GROUP, LLC

High pressure which is present in the fuel rail flows to the ball seat (1) of the solenoid (5). The
specified pressure required by the system is built up in the rail by the fuel pressure regulator building
up a magnetic force which corresponds to this specific pressure by means of a control current from
the Powertrain Control Module (PCM). This magnetic force equals a certain outlet cross section at the
ball seat of the solenoid. The rail pressure is altered as a result of the quantity of fuel which flows off.
The current fuel pressure is signaled by the fuel pressure sensor to the (PCM). The controlled fuel
flows back along the return fuel line, into the tank.

In a de-energized state, the fuel pressure solenoid is closed as the spring force (2) presses the ball
into the ball seat. When driving, the fuel pressure solenoid is constantly open. When engine is
started, the fuel pressure solenoid is held closed by magnetic force. When driving, the pressure of the
fluid counteracts the magnetic force of the coil and the slight spring force.

REMOVAL

WARNING: Observe the following precautions when working on fuel systems: No

sparks, open flames or smoking. Avoid inhaling and swallowing fuel.
Avoid eye and skin contact with fuel. Pour fuels only into suitable and
appropriately marked containers. Wear protective clothing. Failure to
observe these precautions may result in fire, explosion, property damage,
and serious or fatal injury.

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Fig. 92: Left Fuel Rail & Bolts
Courtesy of CHRYSLER GROUP, LLC

NOTE: The fuel pressure regulator is not a serviceable item. If diagnosis has lead you
to replace the fuel pressure regulator, then a new fuel rail must to be installed.

1. Disconnect the negative battery cable.

2. Remove the left fuel rail (1). Refer to RAIL, FUEL, INSTALLATION or RAIL, FUEL,
INSTALLATION.

INSTALLATION

WARNING: Observe the following precautions when working on fuel systems: No

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Fig. 93: Left Fuel Rail & Bolts
Courtesy of CHRYSLER GROUP, LLC

1. Install the left fuel rail (1). Refer to RAIL, FUEL, INSTALLATION or RAIL, FUEL,
INSTALLATION.
2. Connect the negative battery cable.

SENDING UNIT AND SENSOR, FUEL LEVEL

DESCRIPTION

FUEL LEVEL SENDING UNIT AND SENSOR

The fuel level sending units and sensors are integrated with both the main fuel pump module and the
auxiliary fuel pump module and are not serviced separately. The appropriate fuel pump module must
be replace if either fuel level sending unit is to be replaced.

For fuel pump module removal. Refer to MODULE, FUEL PUMP, REMOVAL or MODULE, FUEL
PUMP, REMOVAL.

SENSOR, FUEL PRESSURE

DESCRIPTION

DESCRIPTION
Fig. 94: High Pressure Pump

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Courtesy of CHRYSLER GROUP, LLC

The fuel rail pressure sensor screws into the right fuel rail at the back of the engine. The Powertrain
Control Module (PCM) uses this sensor to monitor the fuel rail pressure. The fuel rail pressure sensor
is not a serviceable item, if diagnosis has led you to replace the fuel rail pressure sensor then the
complete fuel rail has to be replaced.

OPERATION

The fuel rail pressure sensor measures the current fuel rail pressure and supplies an appropriate
voltage signal to the Powertrain Control Module (PCM).

REMOVAL

WARNING: Observe the following precautions when working on fuel systems: No

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Fig. 95: Right Fuel Rail & Bolts
Courtesy of CHRYSLER GROUP, LLC

NOTE: The fuel rail pressure sensor is not a serviceable item. If diagnosis has lead you
to replace the fuel rail pressure sensor, then a new fuel rail must to be installed.

1. Disconnect the negative battery cable.

2. Remove the right fuel rail (1). Refer to RAIL, FUEL, REMOVAL or RAIL, FUEL, REMOVAL.

INSTALLATION

WARNING: Observe the following precautions when working on fuel systems: No

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Courtesy of CHRYSLER GROUP, LLC

1. Install the right fuel rail (1). Refer to RAIL, FUEL, INSTALLATION or RAIL, FUEL,
INSTALLATION.
2. Connect the negative battery cable.

SENSOR, FUEL TEMPERATURE

REMOVAL

The fuel temperature sensor is a combination fuel heater/temperature sensor. Refer to HEATER,
FUEL, REMOVAL.

SENSOR, WATER IN FUEL

DESCRIPTION

DESCRIPTION
Fig. 97: Fuel (WIF) Sensor

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Courtesy of CHRYSLER GROUP, LLC

The Water In Fuel (WIF) sensor (1) is located in the fuel filter housing. The WIF sensor (1) detects the
presence of water in the fuel. If water is present in the fuel, a signal is sent to the Powertrain Control
Module (PCM) and the PCM signals the instrument cluster, over the CAN bus, to illuminate the water
in fuel warning.

OPERATION

The non-dielectric properties of the water allow the sensors probes to close the electronic circuit
when water is present in the system. When diesel fuel is present in the system, its dielectric (does not
conduct electricity well) properties do not allow any electrical contact between the probes. A 12V
power signal is always present in order to illuminate the indicator on the instrument cluster.

REMOVAL

REMOVAL
Fig. 98: Drain Plug & Filter Cover

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Courtesy of CHRYSLER GROUP, LLC

NOTE: Remove any dirt and debris around the fuel filter assembly using a suitable
solvent or compressed air. Area around the fuel filter assembly must be clean
and dry.

1. Disconnect the negative battery cable.

2. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
3. Loosen drain plug (2) and drain fuel filter/water separator into a suitable container.
4. Securely tighten drain plug (2).

Fig. 99: Water In Fuel (WIF) Sensor Wire Harness Connector

Courtesy of CHRYSLER GROUP, LLC
5. Disconnect the Water In Fuel (WIF) sensor wire harness connector (1).

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Fig. 100: Fuel (WIF) Sensor
Courtesy of CHRYSLER GROUP, LLC

6. Remove the water in fuel sensor (5).

7. Remove and discard O-ring seal.

INSTALLATION

Fig. 101: O-Ring Seal & Water In Fuel Sensor

Courtesy of CHRYSLER GROUP, LLC

1. Clean the O-ring sealing area of housing.

NOTE: Lubricate the O-ring seal with clean diesel fluid.

2. Install a new O-ring seal (1) onto Water in Fuel (WIF) sensor (2).

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Fig. 102: Fuel (WIF) Sensor
Courtesy of CHRYSLER GROUP, LLC

3. Install the WIF sensor (1) and securely tighten sensor.

Fig. 103: Water In Fuel (WIF) Sensor Wire Harness Connector

Courtesy of CHRYSLER GROUP, LLC

4. Connect the Water In Fuel (WIF) sensor wire harness connector (1).
5. Lower the vehicle.
6. Connect the negative battery cable.
SEPARATOR AND FILTER, FUEL AND WATER

DESCRIPTION

The fuel filter/water separator housing is located on the left side of the vehicle in front of the fuel tank.
The filter has the task of cleaning the fuel before it is fed to the high-pressure system and ultimately to
the injector nozzles.

1. The fuel filter/water separator housing incorporates the following components:

Two 5 micron fuel filter element.
Water separator
Drain plug
Water In Fuel sensor (WIF)

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Fuel heater/temperature sensor

Fig. 104: Drain Plug & Filter Cover

Courtesy of CHRYSLER GROUP, LLC

Fuel filtering is critical in common-rail systems. Small amounts of impurities may damage the
precision mechanical components over time. Water entering the injection system can also lead to
damage. Servicing the fuel filters (1) is done from the bottom of the fuel filter/water separator housing.

A water reservoir is located at the bottom of the filter to collect any water contained in the fuel. A drain
plug (2) is located on the bottom of the filter housing. The filter housing should be drained if a Water-
in-Fuel message is displayed in the instrument cluster. Water is drained by removing the drain plug.

REMOVAL

REMOVAL
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.

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Fig. 105: Drain Plug & Filter Cover
Courtesy of CHRYSLER GROUP, LLC

1. Disconnect negative battery cable.

2. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
3. Loosen drain plug (2) and drain fuel filter/water separator into a suitable container.
4. Securely tighten drain plug (2).

Fig. 106: Fuel Filter/Water Separator Outlet Fuel Line, Inlet Fuel Line & Fuel (WIF) Sensor
Harness Connector
Courtesy of CHRYSLER GROUP, LLC

5. Disconnect the fuel filter/water separator outlet fuel line (1). Refer to FITTING, QUICK
CONNECT .
6. Disconnect the fuel filter/water separator inlet fuel line (2). Refer to FITTING, QUICK
CONNECT .
7. Disconnect the Water In Fuel (WIF) sensor harness connector (3).

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Fig. 107: Combination Fuel Heater/Temperature Sensor Wire Harness Connector
Courtesy of CHRYSLER GROUP, LLC

8. Disconnect the combination fuel heater/temperature sensor wire harness connector (1).

Fig. 108: Fuel Filter/Water Separator Bracket Nut

Courtesy of CHRYSLER GROUP, LLC
9. Loosen the fuel filter/water separator bracket nut (1).

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Fig. 109: Nuts & Fuel Filter/Water Separator Assembly
Courtesy of CHRYSLER GROUP, LLC

10. Remove nuts (2) and the fuel filter/water separator assembly (1).

INSTALLATION

1. Install the fuel filter/water separator assembly (1). Tighten two nuts (2) to 20 N.m (177 in. lbs.).

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Fig. 111: Fuel Filter/Water Separator Bracket Nut
Courtesy of CHRYSLER GROUP, LLC

2. Tighten the fuel filter/water separator bracket nut (1) to 20 N.m (177 in. lbs.).

Fig. 112: Combination Fuel Heater/Temperature Sensor Wire Harness Connector

Courtesy of CHRYSLER GROUP, LLC

3. Connect the combination fuel heater/temperature sensor wire harness connector (1).
Fig. 113: Fuel Filter/Water Separator Outlet Fuel Line, Inlet Fuel Line & Fuel (WIF) Sensor

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Harness Connector
Courtesy of CHRYSLER GROUP, LLC

4. Connect the Water In Fuel (WIF) sensor wire harness connector (3).
5. Connect the fuel filter/water separator inlet fuel line (2).
6. Connect the fuel filter/water separator outlet fuel line (1).

Fig. 114: Drain Plug & Filter Cover

Courtesy of CHRYSLER GROUP, LLC

7. Make sure fuel filter drain port (2) is closed.

8. Lower the vehicle.
9. Connect the negative battery cable.
10. Start the engine and inspect for leaks.
SOLENOID, FUEL QUANTITY

DESCRIPTION

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Fig. 115: Fuel Quantity Solenoid, Connector & Fasteners
Courtesy of CHRYSLER GROUP, LLC

The fuel quantity solenoid is located in the top of the high pressure pump. The solenoid is pulse width
modulated by the Powertrain Control Module (PCM) and meters the amount of fuel that flows into the
high pressure elements inside of the high pressure pump. The solenoid is also inactive during the first
30 seconds to allow maximum fuel pressure to the fuel rail during start up.

Fig. 116: Fuel Quantity Sensor & O-Ring Seals

Courtesy of CHRYSLER GROUP, LLC
1. The fuel quantity solenoid incorporates a screen filter (1) that may require periodic cleaning. In
the invent that screen filter gets dirty or restricted driveability issues and or fault codes may
occur.

OPERATION

The fuel quantity solenoid is a pulse width modulated valve that controls the amount of fuel sent or
delayed to the high pressure pump elements inside of the high pressure pump. The Powertrain
Control Module (PCM) determines the fuel pressure set point based on engine sensor inputs. If the
actual fuel rail pressure is too low, the PCM commands the solenoid to allow more fuel to flow to the
high pressure pump. This minimizes the difference between the actual fuel rail pressure reading and
the set point. The PCM will also operate the solenoid, delaying fuel if the fuel rail pressure becomes
to high.

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The fuel quantity solenoid is commanded open by the PCM to allow the high pressure pump to build
maximum pressure 1800 bar (26, 106 psi) the solenoid also has fuel tank heat protection function that
meters the exact amount of fuel to prevent excess heated fuel from returning to the fuel tank.

REMOVAL

1. Disconnect the negative battery cable.

2. Remove the cowl panel cover. Refer to COVER, COWL PANEL, REMOVAL .
3. Remove bolts and the strut tower support.
Fig. 117: High Pressure Pump Blocker & Bolts

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Courtesy of CHRYSLER GROUP, LLC

4. Remove bolts (2) and the high pressure pump blocker shield (1).

Fig. 118: Low Pressure Supply & Return

Courtesy of CHRYSLER GROUP, LLC

5. Disconnect the low pressure supply (2) and return (1) lines from high pressure pump. Refer to
FITTING, QUICK CONNECT .
Fig. 119: Fuel Quantity Solenoid Wire Harness Connector

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Courtesy of CHRYSLER GROUP, LLC

6. Disconnect the fuel quantity solenoid wiring harness connector (3).

7. Clean the surrounding area of the fuel quantity solenoid.
8. Remove fasteners (2) and the fuel quantity solenoid (1).

INSTALLATION

1. Clean the sealing surfaces.

2. Inspect the fuel quantity solenoid screen filter (1) and clean as necessary.
3. Install new O-ring seals (1) onto the fuel quantity sensor (2).

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Fig. 121: Fuel Quantity Solenoid Wire Harness Connector
Courtesy of CHRYSLER GROUP, LLC

4. Install the fuel quantity solenoid (1) and securely tighten fasteners (2).
5. Connect the fuel quantity solenoid wiring harness connector (3).

Fig. 122: Low Pressure Supply & Return

Courtesy of CHRYSLER GROUP, LLC
6. Connect the low pressure supply (2) and return (1) lines from high pressure pump.

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Fig. 123: High Pressure Pump Blocker & Bolts
Courtesy of CHRYSLER GROUP, LLC

7. Install the high pressure pump blocker shield (1). Tighten bolts (2) to 25 N.m (18 ft. lbs.).
8. Install the strut tower support and securely tighten bolts.
9. Install the cowl panel cover. Refer to COVER, COWL PANEL, INSTALLATION .
10. Connect the negative battery cable.
11. Start the engine and inspect for leaks.

TANK, FUEL

REMOVAL

1. Perform the draining fuel tank procedure. Refer to DRAINING FUEL TANK .
2. Disconnect the negative battery cable.
3. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
4. Remove the left rear tire.
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Fig. 124: Removing/Installing Rear Wheelhouse Shield
Courtesy of CHRYSLER GROUP, LLC

5. Remove the push-pins (1) that secure the rear wheelhouse shield to the body.
6. Remove the left rear wheelhouse splash shield (2).

Fig. 125: Filler Tube Mounting Screw

Courtesy of CHRYSLER GROUP, LLC

7. Disconnect the fuel filler tube ORVR vent line (2).

8. Remove the fuel filler tube retaining bolt (1).
Fig. 126: Splash Shield DR Side

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Courtesy of CHRYSLER GROUP, LLC

9. Remove the left under body splash shield (1).

Fig. 127: Splash Shield PASS Side

Courtesy of CHRYSLER GROUP, LLC

10. Remove the right underbody splash shield (1).

Fig. 128: Filler Tube Clamp Removed

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Courtesy of CHRYSLER GROUP, LLC

11. Remove the hose clamp from the fuel filler tube.

Fig. 129: Remove/Install Filler Tube

Courtesy of CHRYSLER GROUP, LLC

12. Remove fuel filler tube from the rubber hose on the fuel tank and position aside.
13. Remove the muffler and tailpipe assembly. Refer to MUFFLER, EXHAUST, REMOVAL .
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Fig. 130: Heat Shield
Courtesy of CHRYSLER GROUP, LLC

14. Remove the propeller shaft. Refer to REMOVAL .

15. Remove the fuel filter/water separator assembly. Refer to SEPARATOR AND FILTER, FUEL
AND WATER, REMOVAL.
16. Remove the heat shield retainers (2) and remove the heat shield (1).

Fig. 131: EVAP Line

Courtesy of CHRYSLER GROUP, LLC

17. Disconnect the EVAP line in the right rear wheel well.
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Fig. 132: Vapor Connection On Tank
Courtesy of CHRYSLER GROUP, LLC

18. Disconnect the vapor line.

Fig. 133: Suitable Hydraulic Jack & Fuel Tank Adapter

Courtesy of CHRYSLER GROUP, LLC

19. Using a suitable hydraulic jack (1) and a fuel tank adapter (2), support the fuel tank.
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Fig. 134: Tank Strap Bolts
Courtesy of CHRYSLER GROUP, LLC

20. Remove the fuel tank support strap retaining bolts.

Fig. 135: Tank Straps

Courtesy of CHRYSLER GROUP, LLC

21. Remove the fuel tank support straps.

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Fig. 136: Tank Vent Line Routing
Courtesy of CHRYSLER GROUP, LLC

22. Carefully lower the fuel tank and pull the ORVR vent line through bracket.

Fig. 137: Fuel Tank Assembly

Courtesy of CHRYSLER GROUP, LLC

23. Lower and remove the fuel tank from the vehicle.

INSTALLATION

INSTALLATION
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Fig. 138: Fuel Tank Assembly
Courtesy of CHRYSLER GROUP, LLC

1. If removed, install the fuel pump modules (1 and 3). Refer to MODULE, FUEL PUMP,
INSTALLATION or MODULE, FUEL PUMP, INSTALLATION.

Fig. 139: Suitable Hydraulic Jack & Fuel Tank Adapter

Courtesy of CHRYSLER GROUP, LLC

2. Using a suitable hydraulic jack (1) and a fuel tank adapter (2), support the fuel tank.
3. Carefully raise the fuel tank into position while guiding the ORVR vent line through bracket.
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Fig. 140: Tank Straps
Courtesy of CHRYSLER GROUP, LLC

4. Position the fuel tank support straps.

Fig. 141: Tank Strap Bolts

Courtesy of CHRYSLER GROUP, LLC

5. Install fuel tank support strap retaining bolts and tighten to 27 N.m (20 ft. lbs.).
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Fig. 142: Vapor Connection On Tank
Courtesy of CHRYSLER GROUP, LLC

6. Connect the vapor line.

Fig. 143: EVAP Line

Courtesy of CHRYSLER GROUP, LLC

7. Connect the EVAP line in the right rear wheel well.

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Fig. 144: Heat Shield
Courtesy of CHRYSLER GROUP, LLC

8. Position the heat shield (1) and install the heat shield retainers (2).
9. Install the fuel filter/water separator assembly. Refer to SEPARATOR AND FILTER, FUEL
AND WATER, INSTALLATION.
10. Install the propeller shaft. Refer to INSTALLATION .
11. Install the muffler and tailpipe assembly. Refer to MUFFLER, EXHAUST, INSTALLATION .

Fig. 145: Remove/Install Filler Tube

Courtesy of CHRYSLER GROUP, LLC

12. Connect the fuel filler tube to the rubber hose on the fuel tank.
Fig. 146: Filler Tube Clamp Removed

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Courtesy of CHRYSLER GROUP, LLC

13. Install the hose clamp to the rubber hose connecting the fuel filler tube to the fuel tank and
tighten the clamp to 4 N.m (35 in. lbs.).

Fig. 147: Splash Shield PASS Side

Courtesy of CHRYSLER GROUP, LLC

14. Install the right underbody splash shield (1).

Fig. 148: Splash Shield DR Side

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Courtesy of CHRYSLER GROUP, LLC

15. Install the left underbody splash shield (1).

Fig. 149: Filler Tube Mounting Screw

Courtesy of CHRYSLER GROUP, LLC

16. Connect the ORVR vent line (2).

17. Install the fuel filler tube retaining bolt (1) and tighten to 7 N.m (62 in. lbs.).
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Fig. 150: Removing/Installing Rear Wheelhouse Shield
Courtesy of CHRYSLER GROUP, LLC

18. Position the left rear wheelhouse splash shield (2).

19. Install the push-pins (1) that secure the rear wheelhouse shield to the body.
20. Install the left rear tire.
21. Lower the vehicle.
22. Fill the fuel tank.
23. Connect the negative battery cable.
24. Use the scan tool to pressurize the fuel system and check for leaks.

TUBE(S), FUEL

REMOVAL

FUEL TUBES

WARNING: Observe the following precautions when working on fuel systems: No

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Fig. 151: Engine Cover
Courtesy of CHRYSLER GROUP, LLC

1. Disconnect the negative battery cable.

2. Remove the engine cover (1).

Fig. 152: Turbocharger & Charge Air Cooler (CAC) Hose

Courtesy of CHRYSLER GROUP, LLC

3. Disconnect the Charge Air Cooler (CAC) hose (2) from turbocharger (1).
4. Remove the air cleaner body and air tube. Refer to BODY, AIR CLEANER, REMOVAL or
BODY, AIR CLEANER, REMOVAL or BODY, AIR CLEANER, REMOVAL, 5.7L or BODY, AIR
CLEANER, REMOVAL .
Fig. 153: Left Side Fuel Injector Silencer

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Courtesy of CHRYSLER GROUP, LLC

5. Remove the left side fuel injector silencer (1).

Fig. 154: Left Side Fuel Tubes & Union Nuts

Courtesy of CHRYSLER GROUP, LLC

6. Unscrew union nuts (1 and 3) and remove and discard the left side fuel tubes (2).
7. Install protective caps onto the fuel injectors and fuel rail.
Fig. 155: Right Side Fuel Injector Silencer

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Courtesy of CHRYSLER GROUP, LLC

8. Remove the right side fuel injector silencer (1).

Fig. 156: Right Side Fuel Tubes & Union Nuts

Courtesy of CHRYSLER GROUP, LLC

9. Remove the EGR tube. Refer to TUBE, EXHAUST GAS RECIRCULATION (EGR),
REMOVAL .
10. Unscrew union nuts (1 and 3) and remove and discard the right side fuel tubes (2).
11. Install protective caps onto the fuel injectors and fuel rail.
Fig. 157: High Pressure Pump Blocker & Bolts

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Courtesy of CHRYSLER GROUP, LLC

12. Remove bolts (2) and the fuel pump blocker (1).

Fig. 158: Fuel Tube Securing Bolts & Bracket

Courtesy of CHRYSLER GROUP, LLC

13. Remove nut (1) securing the fuel tube.

14. Remove bolt (3) securing the fuel tube.
15. Remove bolts (4) and the bracket (2) securing the fuel tubes.
Fig. 159: High Pressure Fuel Crossover Tube, Left High Pressure Fuel Tube & Fasteners

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Courtesy of CHRYSLER GROUP, LLC

16. Loosen union nuts (1, 5) and remove the right high pressure fuel tube (2) and discard fuel tube.
17. Loosen union nuts (3, 8) and remove the high pressure fuel crossover tube (4) and discard fuel
tube.
18. Loosen union nuts (6, 9) and remove the left high pressure fuel tube (7) and discard fuel tube.

FUEL INJECTOR RETURN LINES

WARNING: Observe the following precautions when working on fuel systems: No

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Courtesy of CHRYSLER GROUP, LLC

1. Disconnect the negative battery cable.

2. Remove the engine cover (1).
3. Remove the cowl panel cover. Refer to COVER, COWL PANEL, REMOVAL .
4. Remove the air cleaner body and air tube. Refer to BODY, AIR CLEANER, REMOVAL or
BODY, AIR CLEANER, REMOVAL or BODY, AIR CLEANER, REMOVAL, 5.7L or BODY, AIR
CLEANER, REMOVAL .

Fig. 161: Left Side Fuel Injector Silencer

Courtesy of CHRYSLER GROUP, LLC

5. Disconnect the Charge Air Cooler (CAC) hose (2) from turbocharger (1).
6. Remove the left bank fuel injector silencer (1).
Fig. 162: Right Side Fuel Injector Silencer

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Courtesy of CHRYSLER GROUP, LLC

7. Remove the right bank fuel injector silencer (1).

Fig. 163: Fuel Injector, Return Hose, Retaining Tab & Connector
Courtesy of CHRYSLER GROUP, LLC

8. Lift up on locking retaining tab (2) to unlock the lock.

9. Remove the fuel return hose (3) by wiggling hose free at the fuel injector (4).
Fig. 164: Fuel Injector Return Line & Main Low Pressure Return Line

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Courtesy of CHRYSLER GROUP, LLC

10. Remove the fuel injector return line (1) from the main low pressure return line (2).

INSTALLATION

FUEL TUBES

WARNING: Observe the following precautions when working on fuel systems: No

WARNING: High-pressure fuel lines deliver fuel under extreme pressure from the
injection pump to the injectors. This maybe as high as 1800 bar (26, 186
psi). Use extreme caution when inspecting for high-pressure fuel leaks.
Inspect high-pressure fuel leaks with a sheet of cardboard. Wear safety
goggles and adequate protective clothing when servicing fuel system.
Fuel under this amount of pressure can penetrate skin causing serious or
fatal injury.
Fig. 165: High Pressure Fuel Crossover Tube, Left High Pressure Fuel Tube & Fasteners

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Courtesy of CHRYSLER GROUP, LLC

NOTE: Fuel tubes are a one time only use and must be replaced anytime they have
been removed.

1. Install the new left high pressure fuel tube (7) and tighten union nuts (6, 9) finger tight.
2. Install the new high pressure fuel crossover tube (4) and tighten union nuts (3, 8) finger tight.
3. Install the new right high pressure fuel tube (2) and tighten union nuts (1, 6) finger tight.

Fig. 166: Fuel Tube Securing Bolts & Bracket

Courtesy of CHRYSLER GROUP, LLC

4. Install the bracket (2) securing the fuel tubes. Tighten bolts (4) to 11 N.m (97 in. lbs.).
5. Install bolt (3) securing the right fuel tube and tighten to 11 N.m (97 in. lbs.).
6. Install nut (1) securing the left fuel tube and tighten to 11 N.m (97 in. lbs.).

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Fig. 167: High Pressure Fuel Crossover Tube, Left High Pressure Fuel Tube & Fasteners
Courtesy of CHRYSLER GROUP, LLC

7. Tighten the union nuts as follows:

Tighten union nut (1, 3, 8, 9) to 5 N.m (44 in. lbs.) plus an additional 75 degrees turn.
Tighten union nut (5 and 6) to 11 N.m (97 in. lbs.) plus an additional 75 degrees turn.

Fig. 168: High Pressure Pump Blocker & Bolts

Courtesy of CHRYSLER GROUP, LLC

8. Install the fuel pump blocker (1). Tighten bolts (2) to 25 N.m (18 ft. lbs.).
Fig. 169: Right Side Fuel Tubes & Union Nuts

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Courtesy of CHRYSLER GROUP, LLC

NOTE: Fuel tubes are a one time only use and must be replaced anytime they
have been removed.

9. Remove the protective caps from the fuel injectors and fuel rail.
10. Install the new right side fuel tubes (2) and tighten union nuts (1, 3) finger tight:
Tighten union nut (1) to 5 N.m (44 in. lbs.) plus an additional 75 degrees turn.
Tighten union nut (3) to 11 N.m (97 in. lbs.) plus an additional 75 degrees turn.
11. Install the EGR tube. Refer to TUBE, EXHAUST GAS RECIRCULATION (EGR),
INSTALLATION .

Fig. 170: Right Side Fuel Injector Silencer

Courtesy of CHRYSLER GROUP, LLC
12. Install the right side fuel injector silencer (1).

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Fig. 171: Left Side Fuel Tubes & Union Nuts
Courtesy of CHRYSLER GROUP, LLC

13. Remove the protective caps from the fuel injectors and fuel rail.
14. Install new left side fuel tubes (2) and tighten union nuts (1 and 3) finger tight.
Tighten union nut (1) to 5 N.m (44 in. lbs.) plus an additional 75 degrees turn.
Tighten union nut (3) to 11 N.m (97 in. lbs.) plus an additional 75 degrees turn.

Fig. 172: Left Side Fuel Injector Silencer

Courtesy of CHRYSLER GROUP, LLC

15. Install the left side fuel injector silencer (1).

Fig. 173: Turbocharger & Charge Air Cooler (CAC) Hose

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Courtesy of CHRYSLER GROUP, LLC

16. Install the air cleaner body and air tube. Refer to BODY, AIR CLEANER, INSTALLATION or
BODY, AIR CLEANER, INSTALLATION or BODY, AIR CLEANER, INSTALLATION, 5.7L or
BODY, AIR CLEANER, INSTALLATION .
17. Connect the Charge Air Cooler (CAC) hose (2) from turbocharger (1).

Fig. 174: Engine Cover

Courtesy of CHRYSLER GROUP, LLC

18. Connect the negative battery cable.

19. Start engine, allow to warm, turn engine off and inspect for leaks.
20. Install the engine cover (1).

FUEL INJECTOR RETURN LINES

Fig. 175: Fuel Injector Return Line & Main Low Pressure Return Line

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Courtesy of CHRYSLER GROUP, LLC

NOTE: The one-way check valves on the fuel injector lines are not serviceable and
should not be taken apart. If the one-way check valve is bad then a new fuel
injector return line will need to be installed.

1. Inspect the fuel injector return line for cracks and inspect the O-ring seals for damage. Replace
the fuel injector return line if a problem exists.
2. Install the fuel injector return line (1) to the main low pressure return line (2).

Fig. 176: Fuel Injector, Return Hose, Retaining Tab & Connector
Courtesy of CHRYSLER GROUP, LLC

3. Install the fuel injector return line (3) and push down on the lock retaining tab (2) to lock in
place.
Fig. 177: Right Side Fuel Injector Silencer

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Courtesy of CHRYSLER GROUP, LLC

4. Install the right bank fuel injector silencer (1).

Fig. 178: Left Side Fuel Injector Silencer

Courtesy of CHRYSLER GROUP, LLC

5. Install the left bank fuel injector silencer (1).

6. Connect the Charge Air Cooler (CAC) hose (2) from turbocharger (1).
7. Install the air cleaner body and air tube. Refer to BODY, AIR CLEANER, INSTALLATION or
BODY, AIR CLEANER, INSTALLATION or BODY, AIR CLEANER, INSTALLATION, 5.7L or
BODY, AIR CLEANER, INSTALLATION .
8. Install the cowl panel cover. Refer to COVER, COWL PANEL, INSTALLATION .
Fig. 179: Engine Cover

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Courtesy of CHRYSLER GROUP, LLC

9. Install the engine cover (1).

10. Connect the negative battery cable.

TUBE, FUEL TANK FILLER

REMOVAL

Fig. 180: Filler Tube Door

Courtesy of CHRYSLER GROUP, LLC

1. Perform the fuel tank draining procedure. Refer to DRAINING FUEL TANK .
2. Disconnect the negative battery cable.
3. Open the fuel filler door.
4. Remove the fuel filler cap.

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Fig. 181: Removing/Installing Retaining Wire
Courtesy of CHRYSLER GROUP, LLC

5. Remove the retaining wire from inside the fuel filler tube rubber seal.

Fig. 182: Pushing Rubber Back

Courtesy of CHRYSLER GROUP, LLC

6. Start removing the rubber seal from the fuel filler housing.
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Fig. 183: Squeezing Rubber And Pushing In
Courtesy of CHRYSLER GROUP, LLC

7. Squeeze the fuel filler tube rubber seal (1).

Fig. 184: Filler Tube Rubber AT Body Opening

Courtesy of CHRYSLER GROUP, LLC

8. Push the fuel filler tube seal in and out of the fuel filler housing.
9. Raise and the support vehicle.
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Fig. 185: Removing/Installing Rear Wheelhouse Shield
Courtesy of CHRYSLER GROUP, LLC

10. Remove the left rear tire.

11. Remove the push-pins (1) that secure the rear wheelhouse splash shield (2) to the body.
12. Remove the rear wheelhouse splash shield from the vehicle.

Fig. 186: Filler Tube Mounting Screw

Courtesy of CHRYSLER GROUP, LLC

13. Disconnect the fuel filler tube ORVR vent line (2).
14. Remove the fuel filler tube retaining nut (1).
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Fig. 187: Splash Shield DR Side
Courtesy of CHRYSLER GROUP, LLC

15. Remove the under body splash shield (1).

Fig. 188: Filler Tube Clamp Removed

Courtesy of CHRYSLER GROUP, LLC

16. Remove the hose clamp from the fuel filler tube. Leave the hose clamp tight at the fuel tank filler
neck.
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Fig. 189: Remove/Install Filler Tube
Courtesy of CHRYSLER GROUP, LLC

17. Remove the fuel filler tube from the rubber hose on the fuel tank and remove the fuel filler tube
from the vehicle.

INSTALLATION

Fig. 190: Remove/Install Filler Tube

Courtesy of CHRYSLER GROUP, LLC

1. Position the fuel filler tube into the vehicle.

2. Insert the fuel filler tube into the rubber hose at the fuel tank filler neck.

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Fig. 191: Filler Tube
Courtesy of CHRYSLER GROUP, LLC

3. Slide the fuel filler tube hose clamp into position and tighten.

Fig. 192: Filler Tube Mounting Screw

Courtesy of CHRYSLER GROUP, LLC

4. Install the fuel filler tube retaining nut (1) and tighten to 12 N.m (106 in. lbs.).
5. Connect the fuel filler tube ORVR vent line (2).
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Fig. 193: Splash Shield DR Side
Courtesy of CHRYSLER GROUP, LLC

6. Install the underbody splash shield (1).

Fig. 194: Removing/Installing Rear Wheelhouse Shield

Courtesy of CHRYSLER GROUP, LLC

7. Position the rear wheelhouse splash shield (2) to the body and install the push-pins (1).
8. Install the left rear tire.
9. Lower the vehicle.
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Fig. 195: Filler Tube Rubber AT Body Opening
Courtesy of CHRYSLER GROUP, LLC

10. Align the fuel filler tube rubber seal to the fuel filler housing.
11. Pull the fuel filler rubber seal through the fuel filler housing opening.
12. Verify the sheet metal of the fuel filler housing is in the groove of the rubber seal.

Fig. 196: Metal Wire Retaining Wire

Courtesy of CHRYSLER GROUP, LLC

13. Start the metal retaining wire (1) into the groove on the inside of the filler tube rubber seal.
14. Work the retaining wire around the fuel filler tube rubber seal until the fuel filler tube is locked
into position.
15. Connect the negative battery cable.
16. Fill the fuel tank and check for leaks.

FUEL INJECTION, DIESEL

OPERATION

FUEL ECONOMY AND MAINTENANCE

A vehicle that is not properly tuned and maintained cannot be expected to perform at its maximum
efficiency and can have an adverse effect on fuel economy. The following recommendations will
ensure that the vehicle is performing at its maximum efficiency:

Use the recommended motor oil grade. Using the manufacturer's recommended grade of
Mopar® motor oil can improve fuel mileage by 1-2%. Mopar® motor oil labeled "Energy

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Conserving" contains friction-reducing additives.
Check and replace air filters. Replacing a clogged air filter with a new Mopar® air filter can
improve fuel mileage by as much as 10%.
Keep the engine tuned. Repairing a vehicle that is noticeably out of tune can improve fuel
mileage by an average of 4%. Maintaining a vehicle and repairing problems, such as a faulty
oxygen sensor, can improve mileage by as much as 40%.
Keep tires properly inflated. Underinflated tires can lower fuel mileage by 0.4% for every 1 psi
drop in pressure of all four tires.

STANDARD PROCEDURE

INJECTOR QUANTITY ADJUSTMENT

The injector quantity adjustment, or classification of injectors describes the quantity, or fuel delivery
characteristic of the injector. This will make it possible to match the Powertrain Control Module (PCM)
fuel delivery strategy to the mechanical characteristics of the injector within a more narrowly
graduated range. Injector classification can only be performed with a scantool.

The fuel injectors used in this vehicle have a seven digit alphanumeric code, which allows the PCM to
determine the fuel quantity characteristic of each injector.

When carrying out service procedures where the injectors are removed from the cylinder head, it is
important to observe the original locations of each individual injector, as installing an original injector
in the wrong location, vehicle driveability and smoking concerns could result.

If an injector(s) is replaced, or if there is any concern that an injector may not be installed in its
original location, the injector quantity adjustment procedure must be performed with the scan tool in
order to program the quantity classification (seven digit alphanumeric code) to the corresponding
cylinder in the engine control module.

INJECTOR CLASSIFICATION PROCEDURE

NOTE: The engine must not be running for this procedure.

NOTE: If installing a new injector, make a note of the seven digit alphanumeric code.
You will need to enter it into the scan tool during the Injector Quantity
Adjustment procedure.

NOTE: Before performing this procedure, if the PCM has been replaced, or if any
injector has been installed anywhere but its original location, make a note of the
seven digit alphanumeric codes and the physical location of each injector. You
will need to enter them into the scan tool during the Injector Quantity
Adjustment procedure.

1. Turn ignition switch "ON".

2. Using a scantool, select PCM View, then MISCELLANEOUS FUNCTIONS.
3. Select Injector Quantity Adjustment, then NEXT.

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4. If the PCM was replaced, the Injector EEPROM Location procedure must be performed. Select
YES, then NEXT, and follow the directions on the scan tool. Otherwise, go to step 5.
5. Select the injector(s) that has been replaced, access the keyboard function, and type the seven
digit alphanumeric code next to the cylinder number that corresponds to the physical location
where the injector has been installed.
6. Click NEXT. The scan tool will prompt to turn the ignition switch off for 12 seconds.
7. Repeat step 5 and 6 for any other injectors that are new, or have been moved from their original
location. Once injectors are classified, cycle ignition to complete.
8. Once the seven digit alphanumeric codes for all injectors have been entered into the PCM,
cycle ignition to complete the procedure.

SPECIFICATIONS

TORQUE

DESCRIPTION N.m Ft. Lbs. In. Lbs.

Accelerator Pedal
34 25 -
Position Sensor Nut
Crankshaft Position
6 - 53
Sensor Cover Bolt
Crankshaft Position
Sensor Wire Harness 8 - 71
Connector Bracket Bolt
Fuel Injector
33 24 -
Tensioning Claw Bolt
Fuel Rail-to-Cylinder
25 18 -
Head Bolt
25 18 -
High Pressure Fuel
Pump Bolt
High Pressure Fuel
80 59 -
Pump Nut
High Pressure Tube
11 - 97
Support Bracket Bolt
High Pressure Tube
11 - 97
Support Bracket Nut
High Pressure Fuel
Tube to Fuel Injector 11 + 75° - 97 + 75°
Union Nut
High Pressure Tube to
5 + 75° - 44 + 75°
Fuel Rail Union Nut
High Pressure Tube to
High Pressure Pump 11 + 75° - 97 + 75°
Union Nut

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Oxygen Sensor 50 37 -

SPECIAL TOOLS

9717 - Brush, Injector Bore

(Originally Shipped In Kit Number(s) 9910.)
VM.10358 - Remover, Fuel Injector

INJECTOR(S), FUEL

DESCRIPTION

DESCRIPTION - FUEL INJECTORS

WARNING: High-pressure fuel lines deliver fuel under extreme pressure from the
injection pump to the injectors. This may be as high as 1800 bar (26, 106
psi). Use extreme caution when inspecting for high-pressure fuel leaks.
Fuel under this amount of pressure can penetrate skin causing personal
injury or death. Inspect high-pressure fuel leaks with a sheet of
cardboard. Wear safety goggles and adequate protective clothing when
servicing the fuel system.

Three electronically controlled fuel injectors are located on top of each cylinder bank. The injectors
generate a fine fuel atomization at injection pressures of up to 1, 800 bar (26, 106 psi). Each injector
is held in place by a tensioning claw and retaining bolt. A copper seal ring is located on the injector tip
to seal off the injector to the combustion chamber. When servicing the injectors, always replace the
copper seal ring and inspect the seal in the cylinder head cover. Lubricate the body of the injector
with Mopar® 05012249AA - Nickel Antisieze Compound, or Molikote Anti-Fretting Paste (MB part
number A001-989-42-51-10).
OPERATION

OPERATION

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Fig. 197: "Z" Port (Inlet), "A" Port (Outlet)
Courtesy of CHRYSLER GROUP, LLC

The injector receives a single high pressure supply which, once inside the injector, is distributed in
two distinct flows. One mainly supplies the nozzle and the other controls the pressure rod. Both of
these flows also contribute to the lubrication of the injector's moving parts, thanks to consistent
seepage present in an injection system that operates at such a high pressure. There is also
recirculation, which is necessary to dissipate the diesel used to operate the pilot valve for channelling
the seepage. The temperature of the diesel recirculated by the injector can reach very high levels 100
°C (212 °F). The recirculation systems must therefore be equipped with pipes that can withstand
these temperatures. In order to better understand its operation, the injector may be considered as
comprising two parts:

1. The actuator/nozzle, comprising the jet and pressure rod-pin assembly.

2. The control solenoid, comprising the solenoid and valve.

The volume inside the pilot valve and immediately above the actuator is known as the control
capacity, and carries out a vital role in the operation of the injector. It is permanently supplied with
diesel via a "Z" port (inlet) (4). The diesel flows out from this reservoir through a second "A" port
(outlet) (2), whose opening is controlled by the control solenoid valve. The diesel contained in the
control reservoir exerts a pressure that can be modulated and which acts upon the upper surface of
the pressure rod, whose area is AC; the force acting on this area therefore depends on the pressure
within the control volume.

The actuator/nozzle comprises a jet with 7 openings at the end, for the output of diesel, and a
pressure rod-pin assembly. The jet is supplied with pressurized diesel when the pressure rod-pin
assembly is in the raised position. This is raised by an imbalance between the opposing forces acting
on the assembly. There are three forces acting on the pressure rod-pin system:

Spring force Fe exerted in the closing direction and created by the spring which acts on the pin;
this force guarantees the seal of the nozzle when the line pressure drops to zero, avoiding the
formation of drops of fuel in the cylinder.
Force FC which also acts in the closing direction; this is caused by the pressure of the diesel
present in the control volume. This pressure acts on the upper area of the pressure rod.
Force FA exerted in the opening direction, created by the pressure of the fuel present in the
supply volume and acting on the area of the circular crown marked out on the outside by the
sliding diameter of the pin in the jet and on the inside by the sealing diameter of the conical
housing.

The equilibrium of the pressure rod-pin assembly depends on the balance between these three
forces; when the injector is not energized, the pressures in the supply and control volumes are
identical and equal to the line pressure provided by the rail. In this condition: FC + Fe > FA.

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REMOVAL

LEFT BANK

WARNING: Observe the following precautions when working on fuel systems: No

WARNING: High-pressure fuel lines deliver fuel under extreme pressure from the
injection pump to the injectors. This maybe as high as 1800 bar (26, 206
psi). Use extreme caution when inspecting for high-pressure fuel leaks.
Inspect high-pressure fuel leaks with a sheet of cardboard. Wear safety
goggles and adequate protective clothing when servicing fuel system.
Fuel under this amount of pressure can penetrate skin causing serious or
fatal injury.
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Fig. 198: Engine Cover
Courtesy of CHRYSLER GROUP, LLC

1. Disconnect the negative battery cable.

2. Remove the engine cover (1).

Fig. 199: Turbocharger & Charge Air Cooler (CAC) Hose

Courtesy of CHRYSLER GROUP, LLC

3. Disconnect the Charge Air Cooler (CAC) hose (2) from turbocharger (1).
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Fig. 200: CAC Hose Bracket & Bolts
Courtesy of CHRYSLER GROUP, LLC

4. Remove the two (1) bolts securing the CAC hose and bracket (2) to timing cover and position
aside.
5. Remove the air cleaner body and air tube. Refer to BODY, AIR CLEANER, REMOVAL or
BODY, AIR CLEANER, REMOVAL or BODY, AIR CLEANER, REMOVAL, 5.7L or BODY, AIR
CLEANER, REMOVAL .

Fig. 201: Left Side Fuel Injector Silencer

Courtesy of CHRYSLER GROUP, LLC

6. Remove the fuel injector silencer (1).

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Fig. 202: Fuel Injector, Return Hose, Retaining Tab & Connector
Courtesy of CHRYSLER GROUP, LLC

7. Using shop air, clean the area surrounding the fuel injector.
8. Lift up on locking retaining tab (2) to unlock the lock.
9. Disconnect the fuel return hose (3) by wiggling hose free from the top of fuel injector (4).
10. Disconnect the fuel injector harness connector (1).

Fig. 203: Fuel Injector, Hold Down Bolt, Washer & Retaining Claw
Courtesy of CHRYSLER GROUP, LLC

11. Remove the high pressure fuel tubes. Refer to TUBE(S), FUEL, REMOVAL.
12. Remove the fuel injector hold down bolt (2), washer (3), and retaining claw (4).
13. Using your hand, pull fuel injector (1) straight up from cylinder head for removal. Discard lower
sealing washer and place a protective cap over the nozzle.

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Fig. 204: Fuel Injector & Removal Tool
Courtesy of CHRYSLER GROUP, LLC

14. If injector can't be removed by hand, install the (special tool #VM.10358, Remover, Fuel
Injector) tool (1) to remove the fuel injector (2). Discard lower sealing washer and place a
protective cap over the nozzle.

RIGHT BANK

WARNING: Observe the following precautions when working on fuel systems: No

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Courtesy of CHRYSLER GROUP, LLC

1. Disconnect the negative battery cable.

2. Remove the EGR tube. Refer to TUBE, EXHAUST GAS RECIRCULATION (EGR),
REMOVAL .

Fig. 206: Fuel Injector, Return Hose, Retaining Tab & Connector
Courtesy of CHRYSLER GROUP, LLC

3. Using shop air, clean the area surrounding the fuel injector.
4. Lift up on locking retaining tab (2) to unlock the lock.
5. Disconnect the fuel return hose (3) by wiggling hose free at the fuel injector (4).
6. Disconnect the fuel injector harness connector (1).
7. Remove the high pressure fuel tubes. Refer to TUBE(S), FUEL, REMOVAL.
Fig. 207: Fuel Injector, Hold Down Bolt, Washer & Retaining Claw

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Courtesy of CHRYSLER GROUP, LLC

8. Remove the fuel injector hold down bolt (2), washer (3), and retaining claw (4).
9. Using your hand, pull fuel injector (1) straight up from cylinder head for removal. Discard lower
sealing washer and place a protective cap over the nozzle and cylinder head.

Fig. 208: Fuel Injector & Removal Tool

Courtesy of CHRYSLER GROUP, LLC

10. If injector can't be removed by hand, install the (special tool #VM.10358, Remover, Fuel
Injector) (1) to remove the fuel injector (2). Discard lower sealing washer and place a protective
cap over the nozzle.

CLEANING
CLEANING FUEL INJECTORS

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Fig. 209: Fuel Injector & Sealing Washer
Courtesy of CHRYSLER GROUP, LLC

NOTE: Before cleaning the injector recesses, seal the injector holes in the injector
recesses with the appropriate pin to prevent debris from falling into the
recesses and entering the motor.

1. Using a lint-free rag, wipe the cylinder head around the fuel injector.
2. Wipe out injector recesses with a lint-free cloth, then clean with the (special tool #9717, Brush,
Injector Bore).
3. Clean the bottom of the cylinder recess with a round brush.
4. Blow out the recess and clean again with a lint-free cloth and cover over.
5. Perform these steps for each injector recess.

NOTE: DO NOT clean the tip of the injector with a wire brush. Use a lint-free cloth.

6. Clean injector body (1) with a wire brush.

7. Clean injector tips with a lint-free cloth.

NOTE: Do Not apply antiseize lubricant to the injector nozzle, apply only to the
injector body.

8. Grease injector body with antiseize lubricant.

NOTE: Always replace the seals that seal off the injectors at the cylinder head to the
combustion chamber.
INSTALLATION

LEFT BANK

NOTE: Any time a new injector is installed, or if an existing injector is installed in any
location other than its original location, the injector quantity adjustment
procedure must be performed. Refer to FUEL INJECTION, DIESEL, STANDARD
PROCEDURE.

NOTE: DO NOT use a brush to clean around the injector nozzle. DO NOT lubricate area
around injector nozzle. The injector may become restricted with debris.

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NOTE: Be sure a new copper washer/seal is installed on end of injector and the old
seal is removed, before installing in cylinder head.

NOTE: No force should be used in installing the fuel injector. Do not apply any
pressure to the electrical connector or the fuel return port during the
installation process.

Fig. 210: Fuel Injector Seal

Courtesy of CHRYSLER GROUP, LLC

1. Clean injectors and injector bore. Refer to INJECTOR(S), FUEL, CLEANING.

2. Lubricate the new fuel injector seal (1) with clean engine oil, diesel fuel, or all purpose white
grease.
3. Install a new fuel injector seal (1) in the cylinder head cover (2).

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Fig. 211: Fuel Injector & Sealing Washer
Courtesy of CHRYSLER GROUP, LLC

NOTE: Do Not apply any lubricant to the fuel injector nozzle. Care must be taken
not to restrict the discharge orifices in the nozzle.

4. Lubricate the fuel injector body with Mopar® White Lithium Grease.
5. Install a new sealing washer (2) onto the fuel injector (1).

Fig. 212: Fuel Injector, Hold Down Bolt, Washer & Retaining Claw
Courtesy of CHRYSLER GROUP, LLC

6. Install the fuel injector (1), tensioning claws (4), washer (3) and bolt (2). Tighten bolts (2) 33 N.m
(24 ft. lbs.).
7. Install new high pressure fuel tubes. Refer to TUBE(S), FUEL, INSTALLATION.

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Fig. 213: Fuel Injector, Return Hose, Retaining Tab & Connector
Courtesy of CHRYSLER GROUP, LLC

8. Connect the fuel injector harness connector (1).

9. Install the fuel injector return hose (3) and push down on the lock retaining tab (2) to lock in
place.

Fig. 214: Left Side Fuel Injector Silencer

Courtesy of CHRYSLER GROUP, LLC

10. Install the fuel injector silencer (1).

11. Install the air cleaner body and air tube. Refer to BODY, AIR CLEANER, INSTALLATION or
BODY, AIR CLEANER, INSTALLATION or BODY, AIR CLEANER, INSTALLATION, 5.7L or
BODY, AIR CLEANER, INSTALLATION .

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Fig. 215: CAC Hose Bracket & Bolts
Courtesy of CHRYSLER GROUP, LLC

12. Position the CAC hose and bracket (2) to timing cover. Tighten bolts (1) to 11 N.m (97 in. lbs.).

Fig. 216: Turbocharger & Charge Air Cooler (CAC) Hose

Courtesy of CHRYSLER GROUP, LLC

13. Connect the Charge Air Cooler (CAC) hose (2) to turbocharger (1).
14. Connect the negative battery cable.
15. Start the engine and inspect for leaks.
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Fig. 217: Engine Cover
Courtesy of CHRYSLER GROUP, LLC

16. Install the engine cover (1).

RIGHT BANK

NOTE: DO NOT use a brush to clean around the injector nozzle. DO NOT lubricate area
around injector nozzle. The injector may become restricted with debris.

NOTE: Be sure a new copper washer/seal is installed on end of injector and the old
seal is removed, before installing in cylinder head.

NOTE: No force should be used in installing the fuel injector. Do not apply any
pressure to the electrical connector or the fuel return port during the
installation process.
Fig. 218: Fuel Injector Seal

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Courtesy of CHRYSLER GROUP, LLC

1. Clean injectors and injector bore. Refer to INJECTOR(S), FUEL, CLEANING.

2. Lubricate the new fuel injector seal (1) with clean engine oil, diesel fuel, or all purpose white
grease.
3. Install a new fuel injector seal (1) into the cylinder head cover (2).

Fig. 219: Fuel Injector & Sealing Washer

Courtesy of CHRYSLER GROUP, LLC

NOTE: Do Not apply any lubricant to the fuel injector nozzle. Care must be taken
not to restrict the discharge orifices in the nozzle.

4. Lubricate the fuel injector body with Mopar® White Lithium Grease.
5. Install a new sealing washer (2) onto the fuel injector (1).

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Fig. 220: Fuel Injector, Hold Down Bolt, Washer & Retaining Claw
Courtesy of CHRYSLER GROUP, LLC

6. Install the fuel injector (1), tensioning claws (4), washer (3) and bolt (2). Tighten bolts (2) 33 N.m
(24 ft. lbs.).
7. Install new high pressure fuel tubes. Refer to TUBE(S), FUEL, INSTALLATION.

Fig. 221: Fuel Injector, Return Hose, Retaining Tab & Connector
Courtesy of CHRYSLER GROUP, LLC

8. Connect the fuel injector wire harness connector (1).

9. Install the fuel injector return hose (3) and push down on the lock retaining tab (2) to lock in
place.
Fig. 222: EGR Tube & Clamps

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Courtesy of CHRYSLER GROUP, LLC

10. Install the EGR tube. Refer to TUBE, EXHAUST GAS RECIRCULATION (EGR),
INSTALLATION .
11. Connect the negative battery cable.
12. Start engine and inspect for leaks.

Fig. 223: Right Side Fuel Injector Silencer

Courtesy of CHRYSLER GROUP, LLC

13. Install the fuel injector silencer (1).

Fig. 224: Engine Cover

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Courtesy of CHRYSLER GROUP, LLC

14. Install the engine cover (1).

SENSOR, ACCELERATOR PEDAL POSITION

DESCRIPTION

Fig. 225: Accelerator Pedal Position Sensor

Courtesy of CHRYSLER GROUP, LLC

1 - ACCELERATOR PEDAL POSITION SENSOR (APPS)

2 - ACCELERATOR PEDAL ASSEMBLY
The accelerator pedal position sensor (1) is located on the accelerator pedal assembly (2). The driver
supplies the torque requirements for the engine by operating the accelerator pedal in accordance with
the desired speed or acceleration. The pedal sensor converts the mechanical operation of the pedal
into an electrical signal and sends the information to the Powertrain Control Module (PCM). The PCM
adjusts the quantity of the fuel that is injected into the engine.

The accelerator pedal position sensor (1) is serviced as an assembly with the accelerator pedal
assembly (2).

REMOVAL

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Fig. 226: View Of Accelerator Pedal Assembly
Courtesy of CHRYSLER GROUP, LLC

1 - HARNESS CONNECTOR
2 - FASTENERS
3 - ACCELERATOR PEDAL ASSEMBLY

1. Disconnect the negative battery cable.

2. Remove the drivers side lower dash board close out panel.
3. Disconnect the APPS wire harness connector (1).
4. Remove the nuts (2) and the accelerator pedal assembly (3).

INSTALLATION

INSTALLATION
Fig. 227: View Of Accelerator Pedal Assembly

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Courtesy of CHRYSLER GROUP, LLC

1 - HARNESS CONNECTOR
2 - FASTENERS
3 - ACCELERATOR PEDAL ASSEMBLY

1. Install the accelerator pedal assembly (3). Tighten nuts (2) to 34 N.m (25 ft. lbs.).
2. Connect the APPS wire harness connector (1).
3. Install the drivers lower dash board close out panel.
4. Connect the negative battery cable.

SENSOR, AIR TEMPERATURE, NUMBER 2

DESCRIPTION

DESCRIPTION
Fig. 228: Intake Air Temperature Sensor/Boost Pressure Sensor, Fastener & Connector

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Courtesy of CHRYSLER GROUP, LLC

The Intake Air Temperature (IAT) sensor 2 (2) is combined with the Boost Pressure sensor is a
mounted on the top of the intake manifold.

OPERATION

The Intake Air Temperature (IAT) sensor 2 operates as a typical two wire sensor and is used to
monitor the temperature of the air in the Intake Manifold. It receives a 5-Volt signal on the (K48)
Intake Air Temperature Sensor 2 Signal circuit and shares the (K690) ground circuit with the Boost
Pressure Sensor.

REMOVAL

REMOVAL
Fig. 229: Intake Air Temperature Sensor/Boost Pressure Sensor, Fastener & Connector

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Courtesy of CHRYSLER GROUP, LLC

1. The Intake Air Temperature (IAT) sensor 2 (2) is incorporated with the boost pressure sensor.
For removal, refer to SENSOR, BOOST PRESSURE, REMOVAL.

INSTALLATION

Fig. 230: Intake Air Temperature Sensor/Boost Pressure Sensor, Fastener & Connector
Courtesy of CHRYSLER GROUP, LLC

1. The Intake Air Temperature (IAT) sensor 2 (2) is incorporated with the boost pressure sensor.
For installation, refer to SENSOR, BOOST PRESSURE, INSTALLATION.

SENSOR, BOOST PRESSURE

DESCRIPTION

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Fig. 231: Intake Air Temperature Sensor/Boost Pressure Sensor, Fastener & Connector
Courtesy of CHRYSLER GROUP, LLC

The Boost Pressure Sensor (2) is combined with the Intake Air Temperature (IAT) Sensor 2 is a
mounted on the top of the intake manifold.

OPERATION

The Boost Pressure Sensor operates as a typical three wire sensor. It is used to measure the
pressure of the air entering the Turbocharger. It receives a 5-Volt feed on the (K668) Boost Pressure
Sensor 5-Volt Supply circuit and shares the (K690) ground circuit with the Intake Air Temperature
Sensor. The Powertrain Control Module (PCM) receives a signal from the sensor via the (K37) Boost
Pressure Sensor Signal circuit.

DIAGNOSIS AND TESTING

BOOST PRESSURE SENSOR

If the boost pressure sensor fails, the PCM records a DTC into memory and continues to operate the
engine in one of the three limp-in modes. When the PCM is operating in this mode, a loss of power
will be present, as if the turbocharger was not operating. The best method for diagnosing faults with
the boost pressure sensor is with the scan tool. Refer to the Diesel Powertrain Diagnostic information.

REMOVAL

REMOVAL
Fig. 232: Engine Cover

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Courtesy of CHRYSLER GROUP, LLC

1. Disconnect the negative battery cable.

2. Remove the engine cover (1).

Fig. 233: Intake Air Temperature Sensor/Boost Pressure Sensor, Fastener & Connector
Courtesy of CHRYSLER GROUP, LLC

3. Disconnect the boost pressure sensor wire harness connector (1).

4. Remove fastener (3), and the boost pressure sensor (2).

INSTALLATION

INSTALLATION
Fig. 234: Intake Air Temperature Sensor/Boost Pressure Sensor, Fastener & Connector

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Courtesy of CHRYSLER GROUP, LLC

1. Install the boost pressure sensor (2) and securely tighten fastener (3).
2. Connect the boost pressure sensor harness connector (1).

Fig. 235: Engine Cover

Courtesy of CHRYSLER GROUP, LLC

3. Install the engine cover (1).

4. Connect the negative battery cable.

SENSOR, CAMSHAFT POSITION

DESCRIPTION
DESCRIPTION

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Fig. 236: Camshaft Position Sensor, Connector & Bolt
Courtesy of CHRYSLER GROUP, LLC

The Camshaft Position (CMP) sensor is mounted on the left upper timing cover. The hall effect
sensor supplies a signal to the Powertrain Control Module (PCM). The PCM uses the signals sent by
the CMP and the Crankshaft Position (CKP) sensor to determine injection timing.

OPERATION

Fig. 237: Camshaft Position Sensor, Connector & Bolt

Courtesy of CHRYSLER GROUP, LLC

The signal circuit of the camshaft sensor has a voltage of approximately 5V. The camshaft has a
reluctor wheel bolted to the front of left exhaust camshaft, the camshaft signal is approximately 0V.
This 0V to 5V signal is used by the Powertrain Control Module (PCM) for detecting ignition TDC of
cylinder 1 as the engine rotates. If no signal is supplied by the camshaft position sensor, the vehicle
will not start.

REMOVAL

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Fig. 238: Camshaft Position Sensor, Connector & Bolt
Courtesy of CHRYSLER GROUP, LLC

1. Disconnect the negative battery cable.

2. Disconnect Camshaft Position (CMP) sensor wire harness connector (3).
3. Remove bolt (1) and the CMP sensor (2).

INSTALLATION

INSTALLATION
Fig. 239: Camshaft Position Sensor, Connector & Bolt

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Courtesy of CHRYSLER GROUP, LLC

1. Install Camshaft Position (CMP) sensor (2). Tighten bolt (1) to 8 N.m (71 in. lbs.).
2. Connect the CMP wire harness connector (3).
3. Connect the negative battery cable.

SENSOR, CRANKSHAFT POSITION

DESCRIPTION

Fig. 240: Crankshaft Position Sensor & Bolt

Courtesy of CHRYSLER GROUP, LLC
The Crankshaft Position (CKP) sensor (2) is located at the rear of the engine below the crankshaft.
The sensor detects the crankshaft position through a (hall effect) by means of missing segments on
the tone wheel behind flex plate. The powertrain Control Module (PCM) detects TDC position of
cylinder 1 by means of the signal supplied by the sensor. Injection timing is synchronized by means of
the camshaft signal and the crankshaft signal. This sensor is used to detect engine speed.

OPERATION

The crankshaft position and engine speed are detected through a (hall effect) signal. The distance
between the Crankshaft Position (CKP) sensor and the gaps of the tone wheel is fixed by the
installation position.

When the crankshaft rotates, an alternating voltage is generated in the crankshaft position sensor by
the gaps of the tone wheel located behind the flex plate.

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In this case, the metal portion of the tone wheel generates a positive voltage pulse and the gap in the
tone wheel a negative voltage pulse. The distance from the positive to the negative voltage peak
equals the length of the gap.

REMOVAL

Fig. 241: Crankshaft Position Sensor (CKP) Wiring Harness Connector

Courtesy of CHRYSLER GROUP, LLC

1. Disconnect the negative battery cable.

2. Remove the belly pan. Refer to BELLY PAN, REMOVAL .
3. Remove the transmission belly pan.
4. Disconnect the Crankshaft Position Sensor (CKP) wiring harness connector (1).
Fig. 242: Rear Crossmember & Bolts

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Courtesy of CHRYSLER GROUP, LLC

5. Remove the two bolts (4) from the rear engine mount isolator.
6. Using a suitable transmission jack, positioned under the transmission oil pan, raise the
transmission to gain enough clearance to remove the CKP cover.

Fig. 243: CKP Sensor, Seal & Fasteners

Courtesy of CHRYSLER GROUP, LLC

7. Remove bolts (1) and the CKP cover.

Fig. 244: Access Hole, Bolt & CKP Sensor

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Courtesy of CHRYSLER GROUP, LLC

8. Using the access hole shown in illustration, remove bolt (3) and the CKP sensor (2).

INSTALLATION

Fig. 245: Access Hole, Bolt & CKP Sensor

Courtesy of CHRYSLER GROUP, LLC

1. Clean the area and bore around Crankshaft Position (CKP) sensor.
2. Install the CKP sensor (2). Tighten bolt (3) to 6 N.m (53 in. lbs.).
Fig. 246: CKP Sensor, Seal & Fasteners

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Courtesy of CHRYSLER GROUP, LLC

3. Install the CKP sensor cover. Tighten bolts (1) to 8 N.m (71 in. lbs.).

Fig. 247: Rear Crossmember & Bolts

Courtesy of CHRYSLER GROUP, LLC

4. Lower the transmission jack so the weight is resting on the isolator.

5. Install the rear engine mount isolator bolts (4) and tighten to 61 N.m (45 ft. lbs.).
Fig. 248: Crankshaft Position Sensor (CKP) Wiring Harness Connector

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Courtesy of CHRYSLER GROUP, LLC

6. Connect the CKP wire harness connector (1).

7. Install the transmission belly pan.
8. Install the belly pan. Refer to BELLY PAN, INSTALLATION .
9. Connect the negative battery cable.

SENSOR, MASS AIRFLOW (MAF)

DESCRIPTION

Fig. 249: Mass Air Flow Sensor, Air Cleaner Housing Cover & Screws
Courtesy of CHRYSLER GROUP, LLC
The Mass Air Flow (MAF) sensor (3) is located in the air intake port between the air filter and the
turbocharger. The MAF sensor is a hot film thermal flowmeter with an Integrated Temperature sensor
which detects the intake air temperature. The sensor is designed for recording load on combustion
engines with diesel fuel injection and has a cylinder size in accordance with the required air flow rate.

OPERATION

The Powertrain Control Module (PCM) uses the Mass Air Flow (MAF) sensor to measure air density.
The temperature resistor located at the front of the MAF sensor measures the temperature of the inlet
air. By varying the voltage, the electronic circuit regulates the temperature of the heating resistor in
the rear so that it is 320° F (160°C) higher than the temperature of the intake air. The temperature at
the heating resistor is measured by a sensor resistor in-between.

Because the incoming air has a cooling effect, the greater the amount of air that flows in, then the

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higher the voltage of the heating resistor. The heating resistor is therefore a measure of mass of air
flowing past. If a temperature change occurs as a result of a increase or reduction of air flow, the
PCM corrects the voltage at the heating resistor until the temperature difference is again achieved.
This control voltage is use by the PCM as a unit measure for metered air mass.

REMOVAL

Fig. 250: Engine Cover

Courtesy of CHRYSLER GROUP, LLC

1. Disconnect the negative battery cable.

2. Remove the engine cover (1).
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Fig. 251: Mass Air Flow (MAF) Sensor, Connector, Clamp, Air Cleaner Body & Fasteners
Courtesy of CHRYSLER GROUP, LLC

3. Loosen screw clamp (2) and detach the air hose from the Mass Air Flow (MAF) sensor (3).
4. Disconnect the MAF wiring harness connector (1).

Fig. 252: Mass Air Flow Sensor, Air Cleaner Housing Cover & Screws
Courtesy of CHRYSLER GROUP, LLC

5. Remove the screws (2) and the MAF sensor (3) from the air cleaner housing cover (1).

INSTALLATION

INSTALLATION
Fig. 253: Mass Air Flow Sensor, Air Cleaner Housing Cover & Screws

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Courtesy of CHRYSLER GROUP, LLC

1. Position the Mass Air Flow (MAF) sensor (3) to air cleaner housing (1) and install the retaining
screws (2).

Fig. 254: Mass Air Flow (MAF) Sensor, Connector, Clamp, Air Cleaner Body & Fasteners
Courtesy of CHRYSLER GROUP, LLC

2. Connect the air intake hose to the MAF sensor (3) and securely tighten clamp (2).
3. Connect the MAF wiring harness connector (1).
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Fig. 255: Engine Cover
Courtesy of CHRYSLER GROUP, LLC

4. Install the engine cover (1).

5. Connect the negative battery cable.

SENSOR, OXYGEN

REMOVAL

LEFT HAND DRIVE

Fig. 256: Engine Cover

Courtesy of CHRYSLER GROUP, LLC

1. Disconnect the negative battery cable.

2. Remove the engine cover (1).

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Fig. 257: Oxygen Sensor Connector & Ball Stud Fastener
Courtesy of CHRYSLER GROUP, LLC

3. Disconnect the oxygen sensor wire harness connector (1) and wire harness retainer at
transmission fill tube.

Fig. 258: Oxygen Sensor

Courtesy of CHRYSLER GROUP, LLC

4. Remove the oxygen sensor (1).

RIGHT HAND DRIVE

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Fig. 259: Engine Cover
Courtesy of CHRYSLER GROUP, LLC

1. Disconnect the negative battery cable.

2. Remove the engine cover (1).

Fig. 260: Oxygen Sensor Connector & Ball Stud Fastener

Courtesy of CHRYSLER GROUP, LLC
3. Disconnect the oxygen sensor wire harness connector (1) and wire harness retainer at
transmission fill tube.

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Fig. 261: Oxygen Sensor
Courtesy of CHRYSLER GROUP, LLC

4. Remove the oxygen sensor (1).

INSTALLATION

LEFT HAND DRIVE

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Fig. 262: Oxygen Sensor
Courtesy of CHRYSLER GROUP, LLC

1. Install the oxygen sensor (1) and tighten to 50 N.m (37 ft. lbs.).

Fig. 263: Oxygen Sensor Connector & Ball Stud Fastener

Courtesy of CHRYSLER GROUP, LLC

2. Connect the oxygen sensor harness connector (1).

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Fig. 264: Engine Cover
Courtesy of CHRYSLER GROUP, LLC

3. Install the engine cover (1).

4. Connect the negative battery cable.

RIGHT HAND DRIVE

Fig. 265: Oxygen Sensor

Courtesy of CHRYSLER GROUP, LLC

1. Install the oxygen sensor (1) and tighten to 50 N.m (37 ft. lbs.).
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Fig. 266: Oxygen Sensor Connector & Ball Stud Fastener
Courtesy of CHRYSLER GROUP, LLC

2. Connect the oxygen sensor harness connector (1).

Fig. 267: Engine Cover

Courtesy of CHRYSLER GROUP, LLC

3. Install the engine cover (1).

4. Connect the negative battery cable.

FUEL DELIVERY, GAS

STANDARD PROCEDURE

FUEL SYSTEM PRESSURE RELEASE

1. Remove the fuel pump relay from the Power Distribution Center (PDC). Refer to FUSE
LOCATIONS AND TYPES, SPECIFICATIONS . A relay location label can also be found on the
underside of the PDC cover.
2. Start and run the engine until it stalls.

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3. Attempt restarting engine until it will no longer run.
4. Turn ignition key to the OFF position.
5. Return fuel pump relay to the Power Distribution Center (PDC).

NOTE: After servicing the fuel system, one or more Diagnostic Trouble Codes (DTC's)
may have been stored in the Powertrain Control Module (PCM) memory due to
disconnecting the fuel pump module circuit. A diagnostic scan tool must be
used to erase a DTC.

DRAINING FUEL TANK

CONVENTIONAL PROCEDURE

CAUTION: If the electric fuel pump is not operating, and the fuel level is above 5/8 of
a tank, the fuel tank must be removed prior to draining. If the fuel level is
above 5/8 of a tank and the fuel pump module lock-ring is removed, fuel
will spill into the interior of the vehicle.

CAUTION: If the fuel level sending unit is not operating, and the fuel level cannot be
determined the fuel tank must be removed prior to draining. If the fuel level
is above 5/8 of a tank and the fuel pump module lock-ring is removed, fuel
will spill into the interior of the vehicle.

NOTE: Due to a one-way check valve installed into the fuel fill fitting at the tank, the
tank cannot be drained at the fuel filler tube.

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Fig. 268: Fuel Supply Line
Courtesy of CHRYSLER GROUP, LLC

1. Perform the fuel system pressure release procedure. Refer to FUEL SYSTEM PRESSURE
RELEASE .
2. Disconnect the fuel supply line (2) from the fuel rail. Refer to STANDARD PROCEDURE .
Fig. 269: Fuel Line Adapters

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Courtesy of CHRYSLER GROUP, LLC

NOTE: Tool number 8978-2 is used on 5/16" fuel lines while tool number 8531-1 is
used on 3/8" fuel lines.

3. Install the appropriate fuel line adapter fitting from the (special tool #8978A, Decay Tool, Fuel)
to the fuel supply line. Route the opposite end of this hose to an OSHA approved fuel storage
tank such as the JohnDow Gas Caddy 320-FC-P30-A or equivalent.

NOTE: Due to a built in time out feature of the diagnostic scan tool, the fuel pump
may need to be reactivated several times before the fuel tank evacuation is
complete.

4. Using a diagnostic scan tool, activate the fuel pump until the fuel tank has been evacuated.

ALTERNATIVE PROCEDURE

WARNING: No sparks, open flames or smoking. Risk of poisoning from inhaling and
swallowing fuel. Pour fuel only into appropriately marked OSHA approved
containers. Wear protective clothing. Risk of injury to eyes and skin from
contact with fuel.
CAUTION: The fuel level of the vehicle must be below 5/8 of a tank before using the
"Alternative Procedure". If the fuel level is above 5/8 of a tank and the fuel
pump module lock-ring is removed, fuel will spill into the interior of the
vehicle.

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Fig. 270: Negative Battery Cable
Courtesy of CHRYSLER GROUP, LLC

1. Verify the fuel level is below 5/8 of a tank.

2. Perform the fuel system pressure release procedure. Refer to FUEL SYSTEM PRESSURE
RELEASE .
3. Disconnect the negative battery cable (1).
Fig. 271: Pulling Rear Seat Up

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Courtesy of CHRYSLER GROUP, LLC

4. Push the rear lower seat cushion up and back and remove the seat cushion.

Fig. 272: Foam Pad Under Seat

Courtesy of CHRYSLER GROUP, LLC

5. Fold back the foam pad covering the fuel pump module plastic access covers.
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Fig. 273: Locating Plastic Access Cover
Courtesy of CHRYSLER GROUP, LLC

6. Remove the left side fuel pump module plastic access cover.

Fig. 274: Left Side Module Orientation

Courtesy of CHRYSLER GROUP, LLC

7. Disconnect the electrical connector from the fuel pump module.

CAUTION: An indexing arrow is located on top of the fuel pump module to clock
it's position into the fuel tank, note it's location for reassembly.

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Fig. 275: Left Side Module
Courtesy of CHRYSLER GROUP, LLC

NOTE: Prior to removing the fuel pump module, use compressed air to remove
any accumulated dirt and debris from around fuel tank opening.

8. Mark the fuel pump module orientation.

9. Position the SAE Fuel Pump Lock Ring Wrench (special tool #9340, SAE Fuel Pump Lock Ring
Wrench) (1) into the notches on the outside edge of the lock ring.
10. Install a 1/2 inch drive breaker bar into the SAE Fuel Pump Lock Ring Wrench (1).
11. Rotate the breaker bar counterclockwise and remove the lock ring.

CAUTION: Do not spill fuel into the interior of the vehicle.

CAUTION: The lower reservoir of the fuel pump module must be drained before
removal or fuel can spill into the interior of the vehicle.
Fig. 276: Draining Left Side

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Courtesy of CHRYSLER GROUP, LLC

12. Lift the fuel pump module up enough to push a 3/8 inch hose into the fuel tank.
13. Attach the opposite end of this hose to an OSHA approved fuel storage tank such as the
JohnDow Gas Caddy 320-FC-P30-A or equivalent.
14. Using the gas caddy, evacuate the left side of the fuel tank.

Fig. 277: Access Cover Right Side Module

Courtesy of CHRYSLER GROUP, LLC

15. Remove the right side auxiliary fuel pump module plastic access cover (1).
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Fig. 278: Right Side Module Orientation
Courtesy of CHRYSLER GROUP, LLC

16. Disconnect the fuel supply line (2) at the auxiliary fuel pump module (1).

CAUTION: An indexing arrow is located on top of the fuel pump module to clock
it's position into the fuel tank, note it's location for reassembly.

Fig. 279: Right Side Module

Courtesy of CHRYSLER GROUP, LLC
NOTE: Prior to removing the auxiliary fuel pump module, use compressed air to
remove any accumulated dirt and debris from around fuel tank opening.

17. Mark the auxiliary fuel pump module orientation.

18. Position the SAE Fuel Pump Lock Ring Wrench (special tool #9340, SAE Fuel Pump Lock Ring
Wrench) (1) into the notches on the outside edge of the lock ring (2).
19. Install a 1/2 inch drive breaker bar into the SAE Fuel Pump Lock Ring Wrench (special tool
#9340, SAE Fuel Pump Lock Ring Wrench) (1).
20. Rotate the breaker bar counterclockwise and remove the lock ring.

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Fig. 280: Draining Right Side
Courtesy of CHRYSLER GROUP, LLC

21. Lift the auxiliary fuel pump module up enough to push a 3/8 inch hose (1) into the fuel tank.
22. Attach the opposite end of this hose to an OSHA approved fuel storage tank such as the
JohnDow Gas Caddy 320-FC-P30-A or equivalent.
23. Using the gas caddy, evacuate the right side of the fuel tank.

SPECIFICATIONS

FUEL SYSTEM PRESSURE

DESCRIPTION SPECIFICATION
Fuel Pressure 400 kpa ±34 kpa 58 psi ± 5 psi

TORQUE
DESCRIPTION N.m Ft. Lbs. In. Lbs.
Accelerator Pedal to Dash - 12 9 -
Nuts
Fuel Tank Filler Tube - Nut 12 9 -
Fuel Rail - Bolts (3.6L) 9 - 80
Fuel Rail - Bolts (5.7L) 11 8 -
Fuel Tank Strap - Bolts 27 20 -
Hose Clamps 4 - 35
Vapor Canister - Nut 9 - 80

SPECIAL TOOLS

8978A - Decay Tool, Fuel

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9340 - SAE Fuel Pump Lock Ring Wrench
(Originally Shipped In Kit Number(s) 9327, 9327CC, 9397, 9575.)

FITTING, QUICK CONNECT

STANDARD PROCEDURE

QUICK-CONNECT FITTINGS

Different types of quick-connect fittings are used to attach the various fuel system components, lines
and tubes. Some quick-connect fittings require the use of a special tool for disconnection and
removal.

These are the quick-connect fittings:

Redundant Latch Single Button Type Fitting

Single Button Type Fitting
Pinch Type Fitting
Single Tab Type Fitting
Two Tab Type Fitting
Plastic Retainer Ring Type Fitting
Latch Clip Type 1 Fitting
Latch Clip Type 2 Fitting
Wing Type Fitting

DISCONNECTING

WARNING: The fuel system is under a constant pressure (even with engine off).
Before servicing any fuel system hose, fitting or line, fuel system
pressure must be released. Refer to FUEL SYSTEM PRESSURE
RELEASE .

CAUTION: Before separating a Quick-Connect fitting, pay attention to what type of

fitting is being used. Refer to QUICK-CONNECT FITTINGS . This will
prevent unnecessary fitting or fitting latch breakage.

CAUTION: The interior components (O-rings, clips) of quick-connect fittings are not
serviced separately, but new plastic spacers and latches are available for
some types. If service parts are not available, do not attempt to repair the
damaged fitting or fuel line (tube). If repair is necessary, replace the
complete fuel line (tube) assembly.

REDUNDANT LATCH SINGLE BUTTON TYPE FITTING:

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Fig. 281: Redundant Latch & Push Button
Courtesy of CHRYSLER GROUP, LLC

CAUTION: Do not pry or pull up on the push button as damage to the latches of the
quick-connect fitting will occur.

SINGLE BUTTON TYPE FITTING:

Fig. 283: Single Button Fitting

Courtesy of CHRYSLER GROUP, LLC

CAUTION: Do not pry or pull up on the push button as damage to the latches of the
quick-connect fitting will occur.

This type of quick-connect fitting is equipped with a single push button (2) that releases two internal
latches located in the quick-connect fitting. Special tools are not required for removal.

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Fig. 284: Ouick-Connect Fitting Latches
Courtesy of CHRYSLER GROUP, LLC

1. Press on the push button with your thumb, release the internal latches (1).
2. Remove the quick-connect fitting from the fuel system component.

2 BUTTON TYPE FITTING

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Fig. 285: View Of 2-Button Type Fitting
Courtesy of CHRYSLER GROUP, LLC

This type of quick-connect fitting (1) is equipped with two push buttons (2) that releases two internal
latches located in the quick-connect fitting. Special tools are not required for removal.

1. Press on both push buttons with your thumb, release the internal latches.
2. While holding the two push buttons simultaneously, remove the quick-connect fitting from the
fuel system component.

PINCH TYPE FITTING

Fig. 286: View Of Pinch Type Quick-Connect Fitting

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Courtesy of CHRYSLER GROUP, LLC

This type of quick-connect fitting (1) is equipped with two finger tabs (2). Special tools are not
required for removal.

1. Pinch both tabs (2) together and release the quick-connect fitting.
2. Remove the quick-connect fitting from the fuel system component.

SINGLE TAB TYPE FITTING

Fig. 287: View Of Single-Tab Type Fitting

Courtesy of CHRYSLER GROUP, LLC

This type of quick-connect fitting (3) is equipped with a single pull tab (1). The tab is removable. After
tab is removed the quick-connect fitting can be separated from the fuel system component. Special
tools are not required for removal.

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Fig. 288: Disconnecting Single-Tab Type Fitting
Courtesy of CHRYSLER GROUP, LLC

TWO TAB TYPE FITTING

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Fig. 289: Identifying Typical 2-Tab Type Fitting
Courtesy of CHRYSLER GROUP, LLC

1. Squeeze the plastic tabs (1) against the sides of component being serviced with your fingers.
2. Remove the quick-connect fitting from the fuel system component.

PLASTIC RETAINER RING TYPE FITTING

Fig. 290: Plastic Retainer Ring Type Fitting

Courtesy of CHRYSLER GROUP, LLC
This type of fitting can be identified by the use of a round plastic retainer ring (4) usually black in
color. Special tools are not required for removal.

LATCH CLIP TYPE 1 FITTING

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Fig. 291: Tethered, Latch Clip & Screwdriver
Courtesy of CHRYSLER GROUP, LLC

1. Pry up on the latch clip (4) with a screwdriver (3).

2. Slide the latch clip away from the quick-connect fitting while lifting the screwdriver and position
aside.
Fig. 292: Fuel Line Disconnection Using Special Tool

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Courtesy of CHRYSLER GROUP, LLC

3. Insert an appropriate fuel line removal tool (1) into the quick-connect fitting and release the
internal latches.

NOTE: After removal the internal latches will remain in the quick-connect fitting.

4. With the special tool still inserted, remove the quick-connect fitting from the fuel system
component.

LATCH CLIP TYPE 2 FITTING

Fig. 293: Latch Clip

Courtesy of CHRYSLER GROUP, LLC
Depending on vehicle model and engine, 2 different types of safety latch clips are used. One is
tethered to the fuel line and the other is not. A special tool will be necessary to disconnect the fuel line
after the latch clip is removed. The latch clip may be used on certain fuel line and fuel rail connections
or to join fuel lines together.

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Fig. 294: Fuel Line Disconnection Using Special Tool
Courtesy of CHRYSLER GROUP, LLC

3. Insert an appropriate fuel line removal tool (1) into the quick-connect fitting and release the
internal latches.

NOTE: After removal the internal latches will remain in the quick-connect fitting.

4. With the special tool still inserted, remove the quick-connect fitting from the fuel system
component.

WING TYPE FITTING

Fig. 295: EVAP Can. Vapor Hose
Courtesy of CHRYSLER GROUP, LLC

The wing type fitting is used on fuel system and emission components. The wing type fitting is most
commonly used on the EVAP canister (3). Special tools are not required for removal.

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1. Using two fingers, press both wings (2) and release the locking tabs.

NOTE: After removal the locking tabs will remain with the quick-connect fitting.

2. While holding the wings, remove the quick-connect fitting from the fuel system component.

CONNECTING

MODULE, FUEL PUMP

DESCRIPTION
DESCRIPTION

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Fig. 296: Main Fuel Pump Module & Auxiliary Fuel Pump Module
Courtesy of CHRYSLER GROUP, LLC

This vehicle uses a saddle type tank that has a reservoir on both sides of the rear drive shaft. The
main fuel pump module (2) is located on the left side of the vehicle and is a high flow fuel pump
specifically designed for the 6.4L HEMI Engine. The auxiliary fuel pump module (1) is located the
right side of the vehicle. The fuel outlet or fuel supply line is on the auxiliary fuel pump module (right
side) and supplies fuel to the engine. The electrical connector is on the main fuel pump module (left
side) and controls both modules. The fuel pressure regulator is integrated into the auxiliary fuel pump
module and is not a serviceable component.

Both modules have fuel level sending cards. The fuel level sending cards are not serviceable
components. There are 3 hoses that connect the main and auxiliary fuel pump modules together, one
is the fuel supply line the other two are fuel return lines. These lines are removed from the main fuel
pump module when servicing either unit. One fuel filter is used and is located at the bottom of the
main fuel pump module and is designed for extended life. A separate frame mounted fuel filter is not
used with any engine. The fuel filter is not a serviceable component.
Fig. 297: Electrical Connector And Fuel Level Sending Card
Courtesy of CHRYSLER GROUP, LLC

Left side main fuel pump module with electrical connector (1) and fuel level sending card (2).

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Fig. 298: Fuel Supply Fitting, Fuel Return Lines, Fuel Supply Line, Fuel Pressure Regulator
And Fuel Level Sending Card
Courtesy of CHRYSLER GROUP, LLC

Right side auxiliary fuel pump module with the fuel supply fitting (1), fuel return lines (2), fuel supply
line (3), fuel pressure regulator (4) and fuel level sending card (5).

OPERATION

Fig. 299: Fuel System

Courtesy of CHRYSLER GROUP, LLC

The way the fuel pumps work is as follows, fuel enters the reservoir of the main fuel pump module
(driver side). The main fuel pump module (2) pumps the fuel through the filter to the auxiliary fuel
pump module (1) (passenger side) through a supply line inside the fuel tank. The fuel pressure
regulator inside the auxiliary fuel pump module regulates the pressure at 58 psi and sends fuel to the
engine. All unused fuel that is not sent to the engine is fed through a venturi at the bottom of the
auxiliary fuel pump module. This creates a low pressure siphoning effect and draws fuel from the
passenger side of the tank and transfers it to the drivers side tank via siphon hose inside the tank.
While the vehicle is running the fuel in the passenger side of tank is continuously transferred to the
drivers side. Fuel will continue to fill the drivers side tank till it reaches the bridge section and then
starts to spill over to the passenger side.

Both main and auxiliary fuel pumps have fuel level sender cards and the reading of these senders are
averaged out to give us the fuel gauge reading. When diagnosing a fuel level sender concern, the
passenger side reading should never be higher than the drivers side reading. However it is possible,
depending on fuel level and driving habit before diagnosing, to spill fuel over to the passenger side
that might indeed show a lower resistance value than the driver side.

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The fuel gauge gives an indication to the vehicle operator the level of fuel in the fuel tank. This fuel
gauge is controlled by the instrument cluster circuit board based upon cluster programming and a
hard wired inputs received by the cluster from the fuel level sending units integrated into the fuel
pump modules.

The instrument cluster continually monitors both fuel pump sender cards to determine the level of fuel
in the fuel tank. The cluster then sends the proper fuel level messages to other electronic modules in
the vehicle over the Controller Area Network (CAN) data bus. For further diagnosis of the fuel gauge
or the instrument cluster circuitry that controls the gauge. Refer to DIAGNOSIS AND TESTING . The
fuel gauge is serviced as a unit with the instrument cluster.

The technician needs to order the correct part when replacing the main fuel pump module, auxiliary
fuel pump module and/or fuel tank as all are replaced individually.

REMOVAL

MAIN FUEL PUMP MODULE

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Fig. 300: Negative Battery Cable
Courtesy of CHRYSLER GROUP, LLC

1. Verify the fuel level is below 5/8 of a tank.

2. Perform the fuel pressure release procedure. Refer to FUEL SYSTEM PRESSURE RELEASE .
3. If required, perform the draining fuel tank procedure. Refer to DRAINING FUEL TANK .
4. Disconnect the negative battery cable.
Fig. 301: Pulling Rear Seat Up

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Courtesy of CHRYSLER GROUP, LLC

5. Push the rear lower seat cushion up and back and remove the seat cushion.

Fig. 302: Foam Pad Under Seat

Courtesy of CHRYSLER GROUP, LLC

6. Fold back the foam pad covering the fuel pump module plastic access covers.
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Fig. 303: Locating Plastic Access Cover
Courtesy of CHRYSLER GROUP, LLC

7. Remove the left side main fuel pump module plastic access cover.

Fig. 304: Left Side Module Orientation

Courtesy of CHRYSLER GROUP, LLC

8. Disconnect the electrical connector from the main fuel pump module.

CAUTION: An indexing arrow is located on top of the fuel pump module to clock
it's position into the fuel tank, note it's location for reassembly.
Fig. 305: Left Side Module

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Courtesy of CHRYSLER GROUP, LLC

NOTE: Prior to removing the fuel pump module, use compressed air to remove
any accumulated dirt and debris from around fuel tank opening.

9. Mark the main fuel pump module orientation.

10. Position the SAE Fuel Pump Lock Ring Wrench (special tool #9340, SAE Fuel Pump Lock Ring
Wrench) (1) into the notches on the outside edge of the lock ring.
11. Install a 1/2 inch drive breaker bar into the SAE Fuel Pump Lock Ring Wrench (special tool
#9340, SAE Fuel Pump Lock Ring Wrench) (1).

NOTE: The main fuel pump module will spring up slightly when the lock ring is
removed.

12. Rotate the breaker bar counterclockwise and remove the lock ring.

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Courtesy of CHRYSLER GROUP, LLC

Fig. 307: Line Release

Courtesy of CHRYSLER GROUP, LLC

16. Press the quick connect release tab (3) and remove the fuel supply line (1) from the main fuel
pump module.
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Fig. 308: Hose Connections Drivers Side
Courtesy of CHRYSLER GROUP, LLC

17. Disconnect the fuel return lines (1, 2) from the main fuel pump module.

NOTE: Do not spill fuel into the interior of the vehicle.

NOTE: Whenever a fuel pump module is serviced, the rubber O-ring seal must be
replaced.

19. Remove and discard the rubber O-ring seal.

AUXILIARY FUEL PUMP MODULE

Fig. 309: Access Cover Right Side Module

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Courtesy of CHRYSLER GROUP, LLC

NOTE: The Main Fuel Pump Module must be removed for Auxiliary Fuel Pump Module
removal.

1. Remove the main fuel pump module. Refer to MAIN FUEL PUMP MODULE.
2. Remove the auxiliary fuel pump module plastic access cover (1) from the floor pan.

Fig. 310: Right Side Module Orientation

Courtesy of CHRYSLER GROUP, LLC

NOTE: Prior to removing the fuel pump module, use compressed air to remove
any accumulated dirt and debris from around fuel tank opening.
3. Disconnect the fuel supply line (2) from the auxiliary fuel pump module (1).
4. Mark the auxiliary fuel pump module orientation.

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Fig. 311: Right Side Module
Courtesy of CHRYSLER GROUP, LLC

5. Position the SAE Fuel Pump Lock Ring Wrench (special tool #9340, SAE Fuel Pump Lock Ring
Wrench) (1) into the notches on the outside edge of the lock ring (2).
6. Install a 1/2 inch drive breaker bar into the SAE Fuel Pump Lock Ring Wrench (special tool
#9340, SAE Fuel Pump Lock Ring Wrench) (1).
7. Rotate the breaker bar counterclockwise and remove the lock ring (2).

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC

8. Lift the auxiliary fuel pump module up and out of fuel tank while guiding the fuel supply and
return lines out from the left side of the fuel tank.

NOTE: Whenever a fuel pump module is serviced, the rubber O-ring seal must be
replaced.

9. Remove and discard the rubber O-ring seal.

INSTALLATION

MAIN FUEL PUMP MODULE

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Courtesy of CHRYSLER GROUP, LLC

NOTE: The Auxiliary Fuel Pump Module must be installed before the Main Fuel Pump
Module.

1. If the auxiliary fuel pump module is removed. Refer to AUXILIARY FUEL PUMP MODULE.

NOTE: Whenever the fuel pump module is serviced, the rubber O-ring seal must
be replaced.

2. Install a new rubber O-ring seal.

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Courtesy of CHRYSLER GROUP, LLC

5. Connect the fuel supply line (1) to the main fuel pump module.

Fig. 315: Module Electrical Connectors

Courtesy of CHRYSLER GROUP, LLC

CAUTION: Verify the electrical wires are tucked away into the fuel tank so they
don't get pinched between the top of the fuel pump module and the
rubber O-ring seal.
CAUTION: An indexing arrow is located on top of the fuel pump module to clock
it's position into the fuel tank. The fuel pump module must be
installed in the same position as removed.

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Fig. 316: Left Side Module Orientation
Courtesy of CHRYSLER GROUP, LLC

Fig. 317: Left Side Module

Courtesy of CHRYSLER GROUP, LLC

11. Position the lock ring over top of the main fuel pump module.
12. Position the SAE Fuel Pump Lock Ring Wrench (special tool #9340, SAE Fuel Pump Lock Ring
Wrench) (1) into the notches on the outside edge of the lock ring.
13. Install a 1/2 inch drive breaker bar into the SAE Fuel Pump Lock Ring Wrench (special tool
#9340, SAE Fuel Pump Lock Ring Wrench).
14. Rotate the breaker bar clockwise until all seven notches of the lock ring have engaged.

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Fig. 318: Left Side Module Orientation
Courtesy of CHRYSLER GROUP, LLC

15. Connect the electrical connector (1) to the main fuel pump module.
16. Fill the fuel tank and check for leaks around the rubber O-ring seal.

Fig. 319: Locating Plastic Access Cover

Courtesy of CHRYSLER GROUP, LLC

17. Install the main fuel pump module plastic access cover.

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Fig. 320: Foam Pad Under Seat
Courtesy of CHRYSLER GROUP, LLC

18. Lower the foam pad covering back into place.

Fig. 321: Pulling Rear Seat Up

Courtesy of CHRYSLER GROUP, LLC

19. Push the rear lower seat cushion back and down and install the seat cushion.
Fig. 322: Negative Battery Cable

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Courtesy of CHRYSLER GROUP, LLC

20. Connect the negative battery cable.

AUXILIARY FUEL PUMP MODULE

CAUTION: An indexing arrow is located on top of the fuel pump module to clock it's
position into the fuel tank. The fuel pump module must be installed in the
same position as removed.

CAUTION: Do not allow the float arm of the Auxiliary Fuel Pump Module to come in
contact with any part of the fuel tank during removal or installation,
damage to the float arm and fuel level sending card may result.

Fig. 323: Remove/Install Right Side Module

Courtesy of CHRYSLER GROUP, LLC

NOTE: Whenever the fuel pump module is serviced, the rubber O-ring seal must be
replaced.

1. Install a new rubber O-ring seal.

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Fig. 324: Right Side Module
Courtesy of CHRYSLER GROUP, LLC

6. Position the SAE Fuel Pump Lock Ring Wrench (special tool #9340, SAE Fuel Pump Lock Ring
Wrench) (1) into the notches on the outside edge of the lock ring (2).
7. Install a 1/2 inch drive breaker bar into the SAE Fuel Pump Lock Ring Wrench (special tool
#9340, SAE Fuel Pump Lock Ring Wrench) (1).
8. Rotate the breaker bar clockwise until all seven notches of the lock ring have engaged.
Fig. 325: Right Side Module Orientation

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Courtesy of CHRYSLER GROUP, LLC

9. Connect the fuel supply line (2) to auxiliary fuel pump module (1).

Fig. 326: Access Cover Right Side Module

Courtesy of CHRYSLER GROUP, LLC

10. Install the auxiliary fuel pump module plastic access cover (1).
11. Install the main fuel pump module, see. Refer to MAIN FUEL PUMP MODULE.

RAIL, FUEL

REMOVAL

3.6L
WARNING: The fuel system is under constant pressure even with engine off. Before
servicing the fuel rail, fuel system pressure must be released.

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Fig. 327: Negative Battery Cable
Courtesy of CHRYSLER GROUP, LLC

1. Perform the fuel pressure release procedure. Refer to FUEL SYSTEM PRESSURE RELEASE .
2. Disconnect and isolate the negative battery cable (1).

Fig. 328: Engine Cover

Courtesy of CHRYSLER GROUP, LLC

3. Lift the engine cover retaining grommets off the ball studs and remove the engine cover (1).
Fig. 329: Inlet Air Temperature (IAT) Sensor Electrical Connector, Air Inlet Hose

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Assembly & Fasteners
Courtesy of CHRYSLER GROUP, LLC

4. Disconnect the electrical connector (1) from the Inlet Air Temperature (IAT) sensor.
5. Loosen the clamp (2) at the throttle body.
6. Loosen the clamp (3) at the air cleaner housing.
7. Lift the air inlet hose assembly retaining grommet off the ball stud (4).
8. Remove the air inlet hose assembly (5).

Fig. 330: Upper Intake Manifold & Bolts

Courtesy of CHRYSLER GROUP, LLC

9. Remove the upper intake manifold (2). Refer to MANIFOLD, INTAKE, REMOVAL or
MANIFOLD, INTAKE, REMOVAL or MANIFOLD, INTAKE, REMOVAL, 5.7L or MANIFOLD,
INTAKE, REMOVAL .

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Fig. 331: Intake Ports, Insulator & Alignment Posts
Courtesy of CHRYSLER GROUP, LLC

10. Remove the insulator (2) from the left cylinder head cover.

Fig. 332: Fuel Supply Hose & Fuel Injector Electrical Connectors
Courtesy of CHRYSLER GROUP, LLC

11. Disconnect the fuel injector electrical connectors (2).

12. Disconnect the fuel supply hose (1) from the fuel rail. Refer to FITTING, QUICK CONNECT .

CAUTION: The left and right fuel rails are replaced as an assembly. Do not
attempt to separate the rail halves at the connector tube. Due to the
design of this tube, it does not use any clamps. Never attempt to
install a clamping device of any kind on the tube. When removing the
fuel rail assembly for any reason, be careful not to bend or kink the
tube.

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Fig. 333: Fuel Rail & Retaining Bolts
Courtesy of CHRYSLER GROUP, LLC

13. Remove the fuel rail (2) four retaining bolts (1).
14. Lift the fuel rail and the fuel injectors from the lower intake manifold.

CAUTION: When removing the fuel rail from the lower intake manifold, one or
more fuel injectors may remain in the intake manifold resulting in
residual fuel spilling onto the engine from the fuel rail.
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Fig. 334: Fuel Injectors
Courtesy of CHRYSLER GROUP, LLC

15. If required, remove any remaining fuel injectors (1) from the lower intake manifold.

Fig. 335: Fuel Injectors & The Fuel Rail

Courtesy of CHRYSLER GROUP, LLC

NOTE: Number 2 fuel injector removal shown in illustration, all other fuel injectors
similar.

16. If required, remove any remaining fuel injectors (1) from the fuel rail (2).
Fig. 336: O-ring Seals

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Courtesy of CHRYSLER GROUP, LLC

17. Remove and discard all fuel injector O-ring seals (1).

5.7L

WARNING: The fuel system is under constant pressure even with engine off. Before
servicing the fuel rail, fuel system pressure must be released.

CAUTION: The left and right fuel rails are replaced as an assembly. Do not attempt to
separate fuel rail halves at connector tube. Due to design of the connector
tube, it does not use any clamps. Never attempt to install a clamping
device of any kind to the connector tube. When removing fuel rail
assembly for any reason, be careful not to bend or kink the connector
tube.
Fig. 337: Negative Battery Cable

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Courtesy of CHRYSLER GROUP, LLC

1. Perform fuel system pressure release procedure. Refer to FUEL SYSTEM PRESSURE
RELEASE .
2. Disconnect the negative battery cable.
3. Remove fuel tank filler cap.

Fig. 338: Oil Fill Cap & Engine Cover

Courtesy of CHRYSLER GROUP, LLC

4. Remove the engine cover (2).

Fig. 339: Intake Air Temperature (IAT) Sensor, Air Cleaner Housing, Resonator Retaining

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Bolt & Hose Clamp
Courtesy of CHRYSLER GROUP, LLC

5. Disconnect the electrical connector at the Intake Air Temperature (IAT) sensor (1).
6. Loosen the hose clamp at the air cleaner housing (2).
7. Remove the resonator retaining bolt (3).
8. Loosen the hose clamp at the throttle body (4) and remove the resonator.
9. Disconnect electrical connectors at all 8 fuel injectors. Push red colored slider away from
injector (1). While pushing slider, depress tab (2) and remove the connector (3) from the
injector.
10. Disconnect throttle body electrical connectors.

Fig. 340: Fuel Rail Mounting Bolts Tightening Sequence

Courtesy of CHRYSLER GROUP, LLC
11. Disconnect the fuel supply line at the fuel rail. Refer to QUICK-CONNECT FITTINGS .
12. Disconnect the PCV hose.
13. Using the sequence shown in illustration, remove the four fuel rail retaining bolts.
14. Gently rock and lift the left side fuel rail until the fuel injectors just start to clear the machined
holes in the intake manifold.
15. Gently rock and lift the right side fuel rail until the fuel injectors just start to clear the machined
holes in the intake manifold. Repeat this procedure (left/right) until all injectors have cleared the
machined holes.
16. Remove the fuel rail (with injectors attached) from the engine.
17. If the fuel injectors are to be removed. Refer to INJECTOR(S), FUEL, REMOVAL or INJECTOR
(S), FUEL, REMOVAL.

6.4L

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WARNING: The fuel system is under constant pressure even with engine off. Before
servicing the fuel rail, fuel system pressure must be released.

Fig. 341: Negative Battery Cable

Courtesy of CHRYSLER GROUP, LLC

1. Perform fuel system pressure release procedure. Refer to FUEL SYSTEM PRESSURE
RELEASE .
2. Disconnect the negative battery cable.
3. Remove fuel tank filler cap.

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Fig. 342: Engine Covers
Courtesy of CHRYSLER GROUP, LLC

4. Remove the engine cover (2).

Fig. 343: Intake Air Temperature (IAT) Sensor, Air Cleaner Housing & Duct
Courtesy of CHRYSLER GROUP, LLC

5. Disconnect the electrical connector at the Intake Air Temperature (IAT) sensor (4).
6. Loosen the hose clamp at the air cleaner housing (2).
7. Loosen the hose clamp at the throttle body (2) and remove the duct (3).

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Fig. 344: Throttle Body, Connector & Bolts
Courtesy of CHRYSLER GROUP, LLC

8. Disconnect throttle body electrical connector (2).

Fig. 345: Fuel Rail Mounting Bolts Tightening Sequence

Courtesy of CHRYSLER GROUP, LLC

9. Disconnect electrical connectors at all 8 fuel injectors. Push red colored slider away from
injector (1). While pushing slider, depress tab (2) and remove the connector (3) from the
injector.
10. Disconnect the fuel supply line at the fuel rail. Refer to FITTING, QUICK CONNECT .
11. Disconnect the PCV hose.
12. Using the sequence shown in illustration, remove the four fuel rail retaining bolts.
13. Gently rock and lift the left side fuel rail until the fuel injectors just start to clear the machined
holes in the intake manifold.
14. Gently rock and lift the right side fuel rail until the fuel injectors just start to clear the machined
holes in the intake manifold. Repeat this procedure (left/right) until all injectors have cleared the
machined holes.
15. Remove the fuel rail (with injectors attached) from the engine.
16. If the fuel injectors are to be removed. Refer to INJECTOR(S), FUEL, REMOVAL or INJECTOR
(S), FUEL, REMOVAL.

INSTALLATION

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3.6L

Fig. 346: O-ring Seals

Courtesy of CHRYSLER GROUP, LLC

1. Lightly lubricate the new O-ring seals (1) with clean engine oil and position the seals onto the
fuel injector (2).
Fig. 347: O-ring Seals & Fuel Injector

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Courtesy of CHRYSLER GROUP, LLC

2. Install the six fuel injectors into the fuel rail.

Fig. 348: Fuel Rail Bolt Tightening Sequence

Courtesy of CHRYSLER GROUP, LLC

3. Clean out the fuel injector bores in the lower intake manifold.
4. Position the fuel rail (1) onto the lower intake manifold, install the four retaining bolts and using
the sequence shown in illustration, tighten to 7 N.m (62 in. lbs.).
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Fig. 349: Fuel Supply Hose & Fuel Injector Electrical Connectors
Courtesy of CHRYSLER GROUP, LLC

5. Connect the fuel injector electrical connectors (2).

6. Connect the fuel supply hose to the fuel rail (1). Refer to FITTING, QUICK CONNECT .

Fig. 350: Intake Ports, Insulator & Alignment Posts

Courtesy of CHRYSLER GROUP, LLC

7. Install the insulator (2) to the two alignment posts (3) on top of the left cylinder head cover.
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Fig. 351: Upper Intake Manifold Bolt Tightening Sequence
Courtesy of CHRYSLER GROUP, LLC

8. Install the upper intake manifold (1) and support brackets. Refer to MANIFOLD, INTAKE,
INSTALLATION or MANIFOLD, INTAKE, INSTALLATION or MANIFOLD, INTAKE,
INSTALLATION, 5.7L or MANIFOLD, INTAKE, INSTALLATION .

Fig. 352: Inlet Air Temperature (IAT) Sensor Electrical Connector, Air Inlet Hose
Assembly & Fasteners
Courtesy of CHRYSLER GROUP, LLC

9. Position the air inlet hose assembly (5) onto the throttle body and the air cleaner housing.
10. Secure the air inlet hose assembly retaining grommet onto the ball stud (4).
11. Tighten the clamp at the air cleaner housing (3) to 5 N.m (44 in. lbs.).
12. Tighten the clamp (2) at the throttle body to 5 N.m (44 in. lbs.).
13. Connect the Inlet Air Temperature (IAT) sensor electrical connector (1).

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Fig. 353: Engine Cover
Courtesy of CHRYSLER GROUP, LLC

14. Position the engine cover (1) and secure the retaining grommets onto the ball studs.

Fig. 354: Negative Battery Cable

Courtesy of CHRYSLER GROUP, LLC

15. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
16. Start the engine and check for leaks.

5.7L
CAUTION: The left and right fuel rails are replaced as an assembly. Do not attempt to
separate fuel rail halves at connector tube. Due to design of the connector
tube, it does not use any clamps. Never attempt to install a clamping
device of any kind to the connector tube. When removing fuel rail
assembly for any reason, be careful not to bend or kink the connector
tube.

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Fig. 355: Fuel Injector O-Rings, Fuel Rail/Fuel Injector Assembly & Four Fuel Rail Retaining
Bolts
Courtesy of CHRYSLER GROUP, LLC

NOTE: The fuel injector O-rings may be used again, provided no cuts, tears, or
deformation have occurred.

1. If removed, install the fuel injectors onto the fuel rail. Refer to INJECTOR(S), FUEL,
INSTALLATION or INJECTOR(S), FUEL, INSTALLATION.
2. Inspect the fuel injector O-rings (3) and replace if necessary.
3. Clean out the fuel injector machined bores in the intake manifold.
4. Apply a small amount of engine oil to each fuel injector O-ring (3).
Fig. 356: Fuel Rail Mounting Bolts Tightening Sequence

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Courtesy of CHRYSLER GROUP, LLC

5. Position fuel rail/fuel injector assembly (1) into the machined fuel injector bores of the intake
manifold.
6. Guide each injector into the intake manifold using care not to tear the fuel injector O-rings.
7. Push the right fuel rail down until the fuel injectors have bottomed on shoulders.
8. Push the left fuel rail down until the injectors have bottomed on shoulders.
9. Using the sequence shown in illustration, install the four fuel rail retaining bolts (2) and tighten to
11 N.m (8 ft. lbs.).
10. Connect the fuel line (1) to the fuel rail. Refer to STANDARD PROCEDURE .
11. Connect the fuel injector electrical connectors.
12. Connect the PCV hose.

Fig. 357: Intake Air Temperature (IAT) Sensor, Air Cleaner Housing, Resonator Retaining
Bolt & Hose Clamp
Courtesy of CHRYSLER GROUP, LLC

13. Position the resonator onto the throttle body and air cleaner housing.
14. Tighten the hose clamp at the throttle body (4) to 5 N.m (45 in. lbs.).
15. Install the resonator retaining bolt (3) and tighten to 5 N.m (45 in. lbs.).
16. Tighten the hose clamp at the air cleaner housing (2) to 5 N.m (45 in. lbs.).
17. Connect the electrical connector at the Intake Air Temperature (IAT) sensor (1).

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Fig. 358: Oil Fill Cap & Engine Cover
Courtesy of CHRYSLER GROUP, LLC

18. Install the engine cover (2).

19. Start the engine and check for leaks.

6.4L

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Bolts
Courtesy of CHRYSLER GROUP, LLC

NOTE: The fuel injector O-rings may be used again, provided no cuts, tears, or
deformation have occurred.

Fig. 360: Fuel Rail Mounting Bolts Tightening Sequence

Courtesy of CHRYSLER GROUP, LLC
5. Position fuel rail/fuel injector assembly (1) into the machined fuel injector bores of the intake
manifold.
6. Guide each injector into the intake manifold using care not to tear the fuel injector O-rings.
7. Push the right fuel rail down until the fuel injectors have bottomed on shoulders.
8. Push the left fuel rail down until the injectors have bottomed on shoulders.
9. Using the sequence shown in illustration, install the four fuel rail retaining bolts (2) and tighten to
11 N.m (8 ft. lbs.).
10. Connect the fuel line (1) to the fuel rail. Refer to STANDARD PROCEDURE .
11. Connect the fuel injector electrical connectors.
12. Connect the PCV hose.

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Fig. 361: Throttle Body, Connector & Bolts
Courtesy of CHRYSLER GROUP, LLC

13. Install the throttle body electrical connector (2).

Fig. 362: Intake Air Temperature (IAT) Sensor, Air Cleaner Housing & Duct

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Courtesy of CHRYSLER GROUP, LLC

14. Position the duct (3) onto the throttle body and air cleaner housing (1).
15. Tighten the hose clamp at the throttle body and at the air cleaner housing (2) to 5 N.m (45 in.
lbs.).
16. Connect the electrical connector at the Intake Air Temperature (IAT) sensor (4).

Fig. 363: Engine Covers

Courtesy of CHRYSLER GROUP, LLC

17. Install the engine cover (2).

18. Connect the negative battery cable.
19. Start the engine and check for leaks.
REGULATOR, FUEL PRESSURE

DESCRIPTION

The fuel pressure regulator is integrated with the auxiliary fuel pump module and is not serviced
separately. The auxiliary fuel pump module must be replace if the fuel pressure regulator is to be
replaced.

For auxiliary fuel pump module removal. Refer to MODULE, FUEL PUMP, REMOVAL or MODULE,
FUEL PUMP, REMOVAL.

SENDING UNIT AND SENSOR, FUEL LEVEL

DESCRIPTION

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DESCRIPTION

For fuel pump module removal. Refer to MODULE, FUEL PUMP, REMOVAL or MODULE, FUEL
PUMP, REMOVAL.

TANK, FUEL

REMOVAL

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1. Perform the fuel pressure release procedure. Refer to FUEL SYSTEM PRESSURE RELEASE .
2. Perform the draining fuel tank procedure. Refer to DRAINING FUEL TANK .
3. Disconnect the negative battery cable (1).
4. Raise and support the vehicle.
5. Remove the left rear tire.

Fig. 365: Removing/Installing Rear Wheelhouse Shield

Courtesy of CHRYSLER GROUP, LLC

6. Remove the push-pins (1) that secure the rear wheelhouse shield to the body.
7. Remove the left rear wheelhouse splash shield (2).
Fig. 366: Filler Tube Mounting Screw

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Courtesy of CHRYSLER GROUP, LLC

8. Disconnect the fuel filler tube ORVR vent line (2).

9. Remove the fuel filler tube retaining bolt (1).

Fig. 367: Splash Shield DR Side

Courtesy of CHRYSLER GROUP, LLC

10. Remove the under body splash shield (1).

Fig. 368: Filler Tube Clamp Removed

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Courtesy of CHRYSLER GROUP, LLC

11. Remove the hose clamp from the fuel filler tube.

Fig. 369: Remove/Install Filler Tube

Courtesy of CHRYSLER GROUP, LLC

12. Remove fuel filler tube from the rubber hose on the fuel tank and position aside.
Fig. 370: Identifying Clamps & Rear Exhaust System

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Courtesy of CHRYSLER GROUP, LLC

13. Remove the muffler and tailpipe assembly (2). Refer to MUFFLER, EXHAUST, REMOVAL .

Fig. 371: Heat Shield

Courtesy of CHRYSLER GROUP, LLC

14. Remove the propeller shaft. Refer to REMOVAL .

15. Remove the heat shield retainers (2) and remove the heat shield (1).
Fig. 372: Splash Shield PASS Side

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Courtesy of CHRYSLER GROUP, LLC

16. Remove the right underbody splash shield (1).

Fig. 373: EVAP Line

Courtesy of CHRYSLER GROUP, LLC

17. Disconnect the EVAP line in the right rear wheel well.
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Fig. 374: Vapor Connection On Tank
Courtesy of CHRYSLER GROUP, LLC

18. Disconnect the vapor line.

Fig. 375: Fuel Line Disconnected
Courtesy of CHRYSLER GROUP, LLC

19. Disconnect the fuel supply line.

20. Using a suitable hydraulic jack with a fuel tank adapter, support the fuel tank.

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Fig. 376: Tank Strap Bolts
Courtesy of CHRYSLER GROUP, LLC

21. Remove the fuel tank support strap retaining bolts.

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Fig. 377: Tank Straps
Courtesy of CHRYSLER GROUP, LLC

22. Remove the fuel tank support straps.

Fig. 378: Tank Vent Line Routing

Courtesy of CHRYSLER GROUP, LLC

23. Carefully lower the fuel tank and pull the ORVR vent line through bracket.
Fig. 379: Fuel Tank Assembly

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Courtesy of CHRYSLER GROUP, LLC

24. Lower and remove the fuel tank from the vehicle.

INSTALLATION

Fig. 380: Tank Straps

Courtesy of CHRYSLER GROUP, LLC
1. If removed, install the fuel pump modules. Refer to MODULE, FUEL PUMP, INSTALLATION or
MODULE, FUEL PUMP, INSTALLATION.
2. Using a suitable hydraulic jack with a fuel tank adapter, support the fuel tank.
3. Carefully raise the fuel tank into position while guiding the ORVR vent line through bracket.
4. Position the fuel tank support straps.
5. Install fuel tank support strap retaining bolts and tighten to 27 N.m (20 ft. lbs.).

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Fig. 381: Fuel Line Disconnected
Courtesy of CHRYSLER GROUP, LLC

6. Connect the fuel supply line.

Fig. 382: Vapor Connection On Tank

Courtesy of CHRYSLER GROUP, LLC
7. Connect the vapor line.

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Fig. 383: EVAP Line
Courtesy of CHRYSLER GROUP, LLC

8. Connect the EVAP line in the right rear wheel well.

Fig. 384: Heat Shield

Courtesy of CHRYSLER GROUP, LLC

9. Position the heat shield (1) and install the heat shield retainers (2).
10. Install the propeller shaft. Refer to INSTALLATION .
Fig. 385: Identifying Clamps & Rear Exhaust System

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Courtesy of CHRYSLER GROUP, LLC

11. Install the muffler and tailpipe assembly (2). Refer to MUFFLER, EXHAUST, INSTALLATION .

Fig. 386: Remove/Install Filler Tube

Courtesy of CHRYSLER GROUP, LLC

12. Connect the fuel filler tube to the rubber hose on the fuel tank.
Fig. 387: Filler Tube Clamp Removed

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Courtesy of CHRYSLER GROUP, LLC

13. Install the hose clamp to the rubber hose connecting the fuel filler tube to the fuel tank and
tighten the clamp to 4 N.m (35 in. lbs.).

Fig. 388: Filler Tube Mounting Screw

Courtesy of CHRYSLER GROUP, LLC

14. Connect the ORVR vent line (2).

15. Install the fuel filler tube retaining bolt (1) and tighten to 7 N.m (62 in. lbs.).
Fig. 389: Removing/Installing Rear Wheelhouse Shield

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Courtesy of CHRYSLER GROUP, LLC

16. Position the left rear wheelhouse splash shield (2).

17. Install the push-pins (1) that secure the rear wheelhouse shield to the body.
18. Install the left rear tire.

Fig. 390: Splash Shield DR Side

Courtesy of CHRYSLER GROUP, LLC

19. Install the left underbody splash shield (1).

Fig. 391: Splash Shield PASS Side

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Courtesy of CHRYSLER GROUP, LLC

20. Install the right underbody splash shield (1).

21. Lower the vehicle.

Fig. 392: Negative Battery Cable

Courtesy of CHRYSLER GROUP, LLC

22. Fill the fuel tank.

23. Connect the negative battery cable (1).
24. Use the scan tool to pressurize the fuel system and check for leaks.

TUBE, FUEL TANK FILLER

REMOVAL
REMOVAL

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Fig. 393: Negative Battery Cable
Courtesy of CHRYSLER GROUP, LLC

1. Perform the fuel tank draining procedure. Refer to DRAINING FUEL TANK .
2. Disconnect the negative battery cable (1).

Fig. 394: Fuel Filler Door

Courtesy of CHRYSLER GROUP, LLC
3. Open the fuel filler door.
4. Partially raise and support vehicle.

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Fig. 395: Removing/Installing Rear Wheelhouse Shield
Courtesy of CHRYSLER GROUP, LLC

5. Remove the left rear tire.

6. Remove the push-pins (1) that secure the rear wheelhouse splash shield (2) to the body.
7. Remove the rear wheelhouse splash shield from the vehicle.

Fig. 396: Fuel Door Release Solenoid, Electrical Connector, Tabs & Fuel Filler Tube
Housing
Courtesy of CHRYSLER GROUP, LLC

8. From behind the fender. Disconnect the fuel door release solenoid (4) electrical connector (5).
9. Press in the tabs (3) that hold the fuel filler tube housing (1) to the fender.

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Fig. 397: Fuel Filler Support Housing And Position Aside
Courtesy of CHRYSLER GROUP, LLC

NOTE: The manual release cable for the fuel door is routed through a rubber
grommet into the trunk. Complete removal of the filler tube housing is not
necessary for filler tube service.

10. Remove the fuel filler support housing and position aside.

Fig. 398: Fuel Tank Pressure Sensor Electrical Connector, Filler Tube & Fuel Tank Vent
Steel Line
Courtesy of CHRYSLER GROUP, LLC

11. Disconnect the ORVR line (3) at the filler tube.

12. Remove the fuel filler tube retaining nut (5).
13. Raise and support the vehicle.

NOTE: The filler tube connecting hose to the fuel tank is pressure fitted to the
filler tube. To remove the hose. It must be removed from the fuel tank side.

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Fig. 399: Filler Tube Clamp Removed
Courtesy of CHRYSLER GROUP, LLC

14. Remove the hose clamp from the fuel tank. Leave the hose clamp tight at the fuel filler neck.

Fig. 400: Filler Tube Disconnected

Courtesy of CHRYSLER GROUP, LLC

15. Remove the fuel filler tube from the fuel tank and remove the fuel filler tube from below the
vehicle.

INSTALLATION

INSTALLATION
Fig. 401: Filler Tube Disconnected
Courtesy of CHRYSLER GROUP, LLC

1. Position the fuel filler tube into the vehicle.

2. Insert the fuel filler tube hose into the fuel tank filler neck.

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Fig. 402: Filler Tube
Courtesy of CHRYSLER GROUP, LLC

3. Slide the fuel filler tube hose clamp into position and tighten.

Fig. 403: Fuel Tank Pressure Sensor Electrical Connector, Filler Tube & Fuel Tank Vent
Steel Line
Courtesy of CHRYSLER GROUP, LLC

4. Install the fuel filler tube retaining nut (5) and tighten to 12 N.m (9 ft. lbs.).
5. Reconnect the fuel filler tube ORVR line (3).
6. Partially lower vehicle.
Fig. 404: Fuel Filler Housing
Courtesy of CHRYSLER GROUP, LLC

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7. Install the fuel filler housing to the fender.
8. Align the fuel filler tube to the fuel filler housing rubber seal and press the housing into place.
9. Press the housing till it locks into place.

Fig. 405: Fuel Door Release Solenoid, Electrical Connector, Tabs & Fuel Filler Tube
Housing
Courtesy of CHRYSLER GROUP, LLC

10. Connect the fuel door release solenoid electrical connector (5).
Fig. 406: Removing/Installing Rear Wheelhouse Shield
Courtesy of CHRYSLER GROUP, LLC

11. Position the rear wheelhouse splash shield (2) to the body and install the push-pins (1).

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12. Install the left rear tire.
13. Lower the vehicle.

Fig. 407: Negative Battery Cable

Courtesy of CHRYSLER GROUP, LLC

14. Connect the negative battery cable (1).

15. Fill the fuel tank and check for leaks.

FUEL INJECTION, GAS

OPERATION

INJECTION SYSTEM

All engines used in this information have a sequential Multi-Port Electronic Fuel Injection system. The
MPI system is computer regulated and provides precise air/fuel ratios for all driving conditions. The
Powertrain Control Module (PCM) operates the fuel injection system.

The PCM regulates:

Ignition timing
Air/fuel ratio
Emission control devices
Cooling fan
Charging system
Idle speed
Vehicle speed control

Various sensors provide the inputs necessary for the PCM to correctly operate these systems. In

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addition to the sensors, various switches also provide inputs to the PCM.

The PCM can adapt its programming to meet changing operating conditions.

Fuel is injected into the intake port above the intake valve in precise metered amounts through
electrically operated injectors. The PCM fires the injectors in a specific sequence. Under most
operating conditions, the PCM maintains an air fuel ratio of 14.7 parts air to 1 part fuel by constantly
adjusting injector pulse width. Injector pulse width is the length of time the injector is open.

The PCM adjusts injector pulse width by opening and closing the ground path to the injector. Engine
RPM (speed) and manifold absolute pressure (air density) are the primary inputs that determine
injector pulse width.

MODES OF OPERATION

As input signals to the PCM change, the PCM adjusts its response to output devices. For example,
the PCM must calculate a different injector pulse width and ignition timing for idle than it does for
Wide Open Throttle (WOT). There are several different modes of operation that determine how the
PCM responds to the various input signals.

The multi-port fuel injection systems has the following modes of operation:

Ignition switch ON (Zero RPM)

Engine start-up
Engine warm-up
Cruise
Idle
Acceleration
Deceleration
Wide-Open-Throttle
Ignition switch OFF

Within these modes of operation, there are two different types of operation, OPEN LOOP and
CLOSED LOOP.

During OPEN LOOP operation the PCM receives input signals and responds according to preset
PCM programming. Inputs from the upstream and downstream heated oxygen sensors are not
monitored during OPEN LOOP operation, except for heated oxygen sensor diagnostics (they are
checked for shorted conditions at all times).

During CLOSED LOOP operation the PCM monitors the inputs from the upstream and downstream
heated oxygen sensors. The upstream heated oxygen sensor input tells the PCM if the calculated
injector pulse width resulted in the ideal air-fuel ratio of 14.7 to one. By monitoring the exhaust
oxygen content through the upstream heated oxygen sensor, the PCM can fine tune injector pulse
width. Fine tuning injector pulse width allows the PCM to achieve optimum fuel economy combined
with low emissions.

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For the PCM to enter CLOSED LOOP operation, the following must occur:

1. Engine coolant temperature must be over 35°F (1.7°C).

If the coolant is over 35°F (1.7°C) the PCM will wait 38 seconds.
If the coolant is over 50°F (10°C) the PCM will wait 15 seconds.
If the coolant is over 167°F (75°C) the PCM will wait 3 seconds.
For other temperatures the PCM will interpolate the correct waiting time.
2. O2 sensor must read either greater than 0.745 volts or less than 0.29 volt.

OPEN LOOP operation is used for engine start-up (crank), engine warm-up, deceleration with fuel
shutoff and wide open throttle. Under most conditions, acceleration, deceleration (with A/C on), idle
and cruise modes, with the engine at operating temperature occur in CLOSED LOOP operation.

IGNITION SWITCH ON (ZERO RPM) MODE

When the ignition switch activates the fuel injection system, the following actions occur:

The PCM monitors the engine coolant temperature sensor and throttle position sensor input.
The PCM determines basic fuel injector pulse width from this input.
The PCM determines atmospheric air pressure from the MAP sensor input to modify injector
pulse width.

When the key is in the ON position and the engine is not running (zero RPM), the Auto Shutdown
(ASD) and fuel pump relays de-energize after approximately 1 second. Therefore, battery voltage is
not supplied to the fuel pump, ignition coil, fuel injectors and heated oxygen sensors.

ENGINE START-UP MODE

This is an OPEN LOOP mode. If the vehicle is in park or neutral (automatic transaxles) or the clutch
pedal is depressed (manual transaxles) the ignition switch energizes the starter relay when the
engine is not running. The following actions occur when the starter motor is engaged.

If the PCM receives the camshaft position sensor and crankshaft position sensor signals, it
energizes the Auto Shutdown (ASD) relay and fuel pump relay. If the PCM does not receive
both signals within approximately one second, it will not energize the ASD relay and fuel pump
relay. The ASD and fuel pump relays supply battery voltage to the fuel pump, fuel injectors,
ignition coil, (EGR solenoid and PCV heater if equipped) and heated oxygen sensors.
The PCM energizes the injectors (on the 69° falling edge) for a calculated pulse width until it
determines crankshaft position from the camshaft position sensor and crankshaft position
sensor signals. The PCM determines crankshaft position within 1 engine revolution.
After determining crankshaft position, the PCM begins energizing the injectors in sequence. It
adjusts injector pulse width and controls injector synchronization by turning the individual
ground paths to the injectors On and Off.
When the engine idles within ±64 RPM of its target RPM, the PCM compares current MAP

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sensor value with the atmospheric pressure value received during the Ignition Switch On (zero
RPM) mode.

Once the ASD and fuel pump relays have been energized, the PCM determines injector pulse width
based on the following:

MAP
Engine RPM
Battery voltage
Engine coolant temperature
Inlet/Intake air temperature (IAT)
Throttle position
The number of engine revolutions since cranking was initiated

During Start-up the PCM maintains ignition timing at 9° BTDC.

ENGINE WARM-UP MODE

This is an OPEN LOOP mode. The following inputs are received by the PCM:

Manifold Absolute Pressure (MAP)

Crankshaft position (engine speed)
Engine coolant temperature
Inlet/Intake air temperature (IAT)
Camshaft position
Knock sensor
Throttle position
A/C switch status
Battery voltage
Vehicle speed
Speed control
O2 sensors

The PCM adjusts injector pulse width and controls injector synchronization by turning the individual
ground paths to the injectors On and Off.

The PCM adjusts ignition timing and engine idle speed. Engine idle speed is adjusted through the idle
air control motor.

CRUISE OR IDLE MODE

When the engine is at operating temperature this is a CLOSED LOOP mode. During cruising or idle
the following inputs are received by the PCM:

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Manifold absolute pressure
Crankshaft position (engine speed)
Inlet/Intake air temperature
Engine coolant temperature
Camshaft position
Knock sensor
Throttle position
Exhaust gas oxygen content (O2 sensors)
A/C switch status
Battery voltage
Vehicle speed

The PCM adjusts injector pulse width and controls injector synchronization by turning the individual
ground paths to the injectors On and Off.

The PCM adjusts engine idle speed and ignition timing. The PCM adjusts the air/fuel ratio according
to the oxygen content in the exhaust gas (measured by the upstream and downstream heated oxygen
sensor).

The PCM monitors for engine misfire. During active misfire and depending on the severity, the PCM
either continuously illuminates or flashes the malfunction indicator lamp (Check Engine light on
instrument panel). Also, the PCM stores an engine misfire DTC in memory, if 2nd trip with fault.

The PCM performs several diagnostic routines. They include:

Oxygen sensor monitor

Downstream heated oxygen sensor diagnostics during open loop operation (except for shorted)
Fuel system monitor
EGR monitor (if equipped)
Purge system monitor
Catalyst efficiency monitor
All inputs monitored for proper voltage range, rationality.
All monitored components (refer to ON-BOARD DIAGNOSTICS ).

The PCM compares the upstream and downstream heated oxygen sensor inputs to measure catalytic
convertor efficiency. If the catalyst efficiency drops below the minimum acceptable percentage, the
PCM stores a diagnostic trouble code in memory, after 2 trips.

During certain idle conditions, the PCM may enter a variable idle speed strategy. During variable idle
speed strategy the PCM adjusts engine speed based on the following inputs.

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A/C status
Battery voltage
Battery temperature or Calculated Battery Temperature
Engine coolant temperature
Engine run time
Inlet/Intake air temperature
Vehicle mileage

ACCELERATION MODE

This is a CLOSED LOOP mode. The PCM recognizes an abrupt increase in Throttle Position sensor
output voltage or MAP sensor output voltage as a demand for increased engine output and vehicle
acceleration. The PCM increases injector pulse width in response to increased fuel demand.

Wide Open Throttle-open loop

DECELERATION MODE

This is a CLOSED LOOP mode. During deceleration the following inputs are received by the PCM:

A/C status
Battery voltage
Inlet/Intake air temperature
Engine coolant temperature
Crankshaft position (engine speed)
Exhaust gas oxygen content (upstream heated oxygen sensor)
Knock sensor
Manifold absolute pressure
Throttle position sensor
IAC motor (solenoid) control changes in response to MAP sensor feedback

The PCM may receive a closed throttle input from the Throttle Position Sensor (TPS) when it senses
an abrupt decrease in manifold pressure. This indicates a hard deceleration (Open Loop). In
response, the PCM may momentarily turn off the injectors. This helps improve fuel economy,
emissions and engine braking.

WIDE-OPEN-THROTTLE MODE

This is an OPEN LOOP mode. During wide-open-throttle operation, the following inputs are used by
the PCM:

Inlet/Intake air temperature

Engine coolant temperature

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Engine speed
Knock sensor
Manifold absolute pressure
Throttle position

When the PCM senses a wide-open-throttle condition through the Throttle Position Sensor (TPS) it
de-energizes the A/C compressor clutch relay. This disables the air conditioning system and disables
EGR (if equipped).

The PCM adjusts injector pulse width to supply a predetermined amount of additional fuel, based on
MAP and RPM.

IGNITION SWITCH OFF MODE

When the operator turns the ignition switch to the OFF position, the following occurs:

All outputs are turned off, unless 02 Heater Monitor test is being run. Refer to ON-BOARD
DIAGNOSTICS .
No inputs are monitored except for the heated oxygen sensors. The PCM monitors the heating
elements in the oxygen sensors and then shuts down.

FUEL ECONOMY AND MAINTENANCE

Use the recommended motor oil grade. Using the manufacturer's recommended grade of
Mopar® motor oil can improve fuel mileage by 1-2%. Mopar® motor oil labeled "Energy
Conserving" contains friction-reducing additives.
Check and replace air filters. Replacing a clogged air filter with a new Mopar® air filter can
improve fuel mileage by as much as 10%.
Keep the engine tuned. Repairing a vehicle that is noticeably out of tune can improve fuel
mileage by an average of 4%. Maintaining a vehicle and repairing problems, such as a faulty
oxygen sensor, can improve mileage by as much as 40%.
Keep tires properly inflated. Underinflated tires can lower fuel mileage by 0.4% for every 1 psi
drop in pressure of all four tires.

FUEL CORRECTION OR ADAPTIVE MEMORIES

OPERATION

SHORT TERM

Short Term Adaptive or Short Term Fuel Trim (STFT) is an immediate correction to fuel injector pulse
width. During Closed Loop operation, Short Term Adaptive makes immediate adjustments to fuel

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delivery in direct response to the signal from the upstream O2 sensor. The PCM infers air/fuel ratio by
monitoring oxygen content measured by the upstream O2 stream sensor.

This is an immediate response to the O2 sensor signal that is not switching or is consistently high or
low. If the upstream oxygen sensor voltage is not consistently switching between 2.5 and 3.5 volts,
the PCM knows that the base pulse width calculation needs to be modified by adjusting the injector
pulse width until the correct O2 sensor voltage is achieved. The need to adjust the injector pulse
width may be a result of vehicle operating conditions, engine wear, fuel quality, etc. The maximum
range of authority for Short Term Adaptive is ±33%. Short Term Adaptive values are not stores when
the ignition is off.

LONG TERM

The main function of Long Term Adaptive is to make fuel corrections that permit Short Term Adaptive
to hover around zero. In order to maintain correct emissions throughout all operating ranges of the
engines, a cell structure based on engine RPM and load (MAP) is used.

There are 26 cells used for the NGC. Two of the cells are used only during idle, as determined by
throttle position and park/neutral switch input. The other cells each represent a given off-idle manifold
pressure and RPM range.

After the vehicle has reached full operating temperature, short term correction factors will update
Long Term Adaptive Memory cells based on vehicle load (RPM/MAP) to allow the Short Term
Adaptive value to be brought back to near zero. Once this correction factor is updated in the memory,
it will be used by the PCM under all operating conditions, open loop and closed loop. However, the
values stored in the Long-term are updated only after the vehicle has entered long-term closed loop
at full operating temperature. This is done to prevent any transition temperature or start-up
compensation form corrupting long term fuel correction.

Long Term and Short Term Adaptive can each change the pulse width by as much as ±33% for a
maximum total correction of ±66% from base pulse width calculation. Long Term Adaptive values are
used during both Open Loop and Closed Loop operation.

SYSTEM DIAGNOSIS

OPERATION

The PCM can test many of its own input and output circuits. If the PCM senses a fault in a major
system, the PCM stores a Diagnostic Trouble Code (DTC) in memory.

For DTC information see On-Board Diagnostics. Refer to MODULE, POWERTRAIN CONTROL,
DESCRIPTION .

SPECIFICATIONS

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DESCRIPTION N.m Ft. Lbs. In. Lbs.
Camshaft Position Sensor - Bolt (3.6L) 8 - 71
Camshaft Position Sensor - Bolt (5.7L) 12 9 -
Crankshaft Position Sensor - Bolt
12 9 -
(3.6L)
Crankshaft Position Sensor - Bolt
12 9 -
(5.7L)
Coolant Temperature Sensor 11 8 -
(3.6L/5.7L)
Knock Sensor - Bolt (3.6L) 23 17 -
Knock Sensor - Bolt (5.7L) 20 15 -
Oxygen Sensor (3.6L/5.7L) 41 30 -
Powertrain Control Module - Bolts 4 - 35
Throttle Body - Bolts (3.6L) 6 - 53
Throttle Body - Bolts (5.7L) 12 9 -
Throttle Body Bracket - Bolts (3.6L) 27 20 -
Short Runner Valve - Bolts (5.7L) 7 - 62
Fuel Rail - Bolts (3.6L) 9 - 80
Fuel Rail - Bolts (5.7L) 11 8 -

INJECTOR(S), FUEL

REMOVAL

3.6L

WARNING: The fuel system is under constant pressure even with engine off. Before
servicing the fuel rail, fuel system pressure must be released.
Fig. 408: Negative Battery Cable
Courtesy of CHRYSLER GROUP, LLC

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1. Perform the fuel pressure release procedure. Refer to FUEL SYSTEM PRESSURE RELEASE .
2. Disconnect and isolate the negative battery cable (1).

Fig. 409: Engine Cover

Courtesy of CHRYSLER GROUP, LLC

3. Lift the engine cover retaining grommets off the ball studs and remove the engine cover (1).
Fig. 410: Inlet Air Temperature (IAT) Sensor Electrical Connector, Air Inlet Hose
Assembly & Fasteners

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Courtesy of CHRYSLER GROUP, LLC

Fig. 411: Fuel Rail & Retaining Bolts

Courtesy of CHRYSLER GROUP, LLC

9. Remove the upper intake manifold and fuel rail (2). Refer to RAIL, FUEL, REMOVAL or RAIL,
FUEL, REMOVAL.

Fig. 412: Fuel Injectors & The Fuel Rail

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Courtesy of CHRYSLER GROUP, LLC

NOTE: Number 2 fuel injector removal shown in illustration, all other fuel injectors
similar.

10. Remove the fuel injectors (1) from the fuel rail (2).

Fig. 413: Fuel Injectors

Courtesy of CHRYSLER GROUP, LLC

NOTE: Number 2 fuel injector removal shown in illustration, all other fuel injectors
similar.

11. Remove the fuel injectors (1) from the lower intake manifold.
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Fig. 414: O-ring Seals
Courtesy of CHRYSLER GROUP, LLC

12. Remove and discard all fuel injector O-ring seals (1).

5.7L

Fig. 415: Fuel Injector O-Rings, Fuel Rail/Fuel Injector Assembly & Four Fuel Rail Retaining
Bolts
Courtesy of CHRYSLER GROUP, LLC

NOTE: Right side shown in illustration, left side similar.

WARNING: The fuel system is under constant pressure even with engine off. Before
servicing fuel injector(s), fuel system pressure must be released.

NOTE: To remove one or more fuel injectors, the fuel rail assembly must be removed
from engine.

1. Perform the fuel system pressure release procedure. Refer to FUEL SYSTEM PRESSURE
RELEASE .
2. Remove the fuel rail assembly (1). Refer to RAIL, FUEL, REMOVAL or RAIL, FUEL,
REMOVAL.
3. Remove the fuel injector retaining clip(s) (2) from the fuel rail (1).
4. Remove the injector(s) from the fuel rail assembly.

INSTALLATION

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3.6L

Fig. 416: O-ring Seals

Courtesy of CHRYSLER GROUP, LLC

1. Lightly lubricate the new O-ring seals (1) with clean engine oil and position the seals onto the
fuel injector (2).
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Fig. 417: O-ring Seals & Fuel Injector
Courtesy of CHRYSLER GROUP, LLC

NOTE: Number 2 fuel injector installation shown in illustration, all other fuel
injectors similar.

2. Install the fuel injectors (1) into the fuel rail (2).

Fig. 418: Fuel Rail Bolt Tightening Sequence

Courtesy of CHRYSLER GROUP, LLC

3. Install the fuel rail and upper intake manifold. Refer to RAIL, FUEL, INSTALLATION or RAIL,
FUEL, INSTALLATION.
Fig. 419: Inlet Air Temperature (IAT) Sensor Electrical Connector, Air Inlet Hose

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Assembly & Fasteners
Courtesy of CHRYSLER GROUP, LLC

4. Position the air inlet hose assembly (5) onto the throttle body and the air cleaner housing.
5. Secure the air inlet hose assembly retaining grommet onto the ball stud (4).
6. Tighten the clamp at the air cleaner housing (3) to 5 N.m (44 in. lbs.).
7. Tighten the clamp (2) at the throttle body to 5 N.m (44 in. lbs.).
8. Connect the Inlet Air Temperature (IAT) sensor electrical connector (1).

Fig. 420: Engine Cover

Courtesy of CHRYSLER GROUP, LLC

9. Lift the engine cover retaining grommets off the ball studs and remove the engine cover (1).

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Fig. 421: Negative Battery Cable
Courtesy of CHRYSLER GROUP, LLC

10. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
11. Start the engine and check for leaks.

5.7L

Fig. 422: Fuel Injector O-Rings, Fuel Rail/Fuel Injector Assembly & Four Fuel Rail Retaining
Bolts
Courtesy of CHRYSLER GROUP, LLC
NOTE: Right side shown in illustration, left side similar.

NOTE: The fuel injector O-rings may be used again, provided no cuts, tears, or
deformation have occurred.

1. Inspect the fuel injector O-rings (3) and replace if necessary.

2. Apply a small amount of engine oil to each fuel injector O-rings.
3. Install the fuel injector(s) into the fuel rail and install the retaining clip(s) (2).
4. Install the fuel rail assembly (1) Refer to RAIL, FUEL, INSTALLATION or RAIL, FUEL,
INSTALLATION.
5. Start the engine and check for leaks.

PEDAL, ACCELERATOR

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REMOVAL

REMOVAL

Fig. 423: Negative Battery Cable

Courtesy of CHRYSLER GROUP, LLC

1. Disconnect the negative battery cable (1).

Fig. 424: Cable Attachment To Accelerator Module

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Courtesy of CHRYSLER GROUP, LLC

2. If equipped with adjustable pedals, remove the adjuster cable (1) at accelerator pedal adjuster
motor (2).

Fig. 425: Accelerator Pedal Adjuster Motor & Electrical Connectors

Courtesy of CHRYSLER GROUP, LLC

CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position

Sensor (APPS) from the accelerator pedal assembly. The APPS and
the accelerator pedal is replaced as an assembly. If the sensor is
removed from the pedal, the electronic calibration may be destroyed.

3. Disconnect the electrical connector at the accelerator pedal adjuster motor (1).
4. Disconnect both electrical connectors at the APPS (2).

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Fig. 426: 3 Retaining Nuts & Pedal Assembly
Courtesy of CHRYSLER GROUP, LLC

5. Remove the pedal assembly 3 retaining nuts (2, 3).

6. Remove the pedal assembly (1).

INSTALLATION

INSTALLATION
Fig. 427: 3 Retaining Nuts & Pedal Assembly

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Courtesy of CHRYSLER GROUP, LLC

1. Position the pedal assembly (1) to the mounting studs.

2. Install the pedal assembly 3 retaining nuts (2, 3) and tighten to 34 N.m (25 ft. lbs.).

Fig. 428: Accelerator Pedal Adjuster Motor & Electrical Connectors

Courtesy of CHRYSLER GROUP, LLC

3. Connect both electrical connectors at the APPS (2).

4. Connect the electrical connector at the accelerator pedal adjuster motor (1).
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Fig. 429: Negative Battery Cable
Courtesy of CHRYSLER GROUP, LLC

5. Connect the negative battery cable (1).

Fig. 430: Cable Attachment To Accelerator Module

Courtesy of CHRYSLER GROUP, LLC

6. If equipped with adjustable pedals, synchronize the accelerator pedal to the brake pedal and
then connect the adjuster cable (1) to the accelerator pedal adjuster motor (2). Refer to PEDAL
(S), BRAKE AND/OR ACCELERATOR, INSTALLATION or PEDAL(S), BRAKE AND/OR
ACCELERATOR, ADJUSTABLE, INSTALLATION .

SENSOR, AIR TEMPERATURE, INLET

REMOVAL

3.6L

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Fig. 431: Negative Battery Cable
Courtesy of CHRYSLER GROUP, LLC

1. Disconnect and isolate the negative battery cable (1).

Fig. 432: Engine Cover

Courtesy of CHRYSLER GROUP, LLC

2. Lift the engine cover retaining grommets off the ball studs and remove the engine cover (1).
Fig. 433: Inlet Air Temperature Sensor Electrical Connector

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Courtesy of CHRYSLER GROUP, LLC

3. Disconnect the electrical connector (1) from the Inlet Air Temperature (IAT) sensor.

Fig. 434: View Of IAT Sensor Tab/O-Ring - 3.7L/4.7L/5.7L

Courtesy of CHRYSLER GROUP, LLC

4. Clean any dirt from the air inlet tube at the IAT sensor base.
5. Gently lift the small plastic release tab (3), rotate the sensor about 1/4 turn counterclockwise
and remove the sensor from the inlet air hose.
6. The IAT sensor O-ring (2) can be reused if not damaged.

5.7L
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Fig. 435: Sensor Location
Courtesy of CHRYSLER GROUP, LLC

The Inlet Manifold Air Temperature (IAT) sensor is installed into the rubber air intake hose near front
of throttle body.

1. Disconnect electrical connector from IAT sensor.

2. Clean dirt from sensor base.
3. Pull sensor from rubber hose.

INSTALLATION

3.6L
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Fig. 436: View Of IAT Sensor Tab/O-Ring - 3.7L/4.7L/5.7L
Courtesy of CHRYSLER GROUP, LLC

1. The Inlet Air Temperature (IAT) sensor O-ring seal (2) can be reused if not damaged.
2. Clean the IAT sensor mounting hole in the air inlet hose.
3. Install the IAT sensor into the air inlet hose and rotate clockwise until the release tab (3)
engages.

Fig. 437: Inlet Air Temperature Sensor Electrical Connector

Courtesy of CHRYSLER GROUP, LLC

4. Install the electrical connector (1) to the IAT sensor.

Fig. 438: Engine Cover

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Courtesy of CHRYSLER GROUP, LLC

5. Position the engine cover (1) and secure the retaining grommets onto the ball studs.

Fig. 439: Negative Battery Cable

Courtesy of CHRYSLER GROUP, LLC

6. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

5.7L
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Fig. 440: Sensor Orientation
Courtesy of CHRYSLER GROUP, LLC

1. Press sensor into rubber air hose.

2. Rotate sensor into position as shown in illustration. For proper system operation, sensor
must be positioned as shown in illustration.

Fig. 441: Sensor Location

Courtesy of CHRYSLER GROUP, LLC
3. Connect electrical connector to sensor.

SENSOR, CRANKSHAFT POSITION

DESCRIPTION

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Fig. 442: Crankshaft Position Sensor
Courtesy of CHRYSLER GROUP, LLC

The Crankshaft Position (CKP) sensor (1) is a hall effect device combined with an internal magnet.

The CKP sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted
into a machined hole.

OPERATION

OPERATION
Fig. 443: Identifying Crankshaft Position Sensor And Tone Wheel (3.7L V-6)

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Courtesy of CHRYSLER GROUP, LLC

The engine speed and crankshaft position are provided through the CKP (Crankshaft Position) sensor
(3). The sensor generates pulses which sends an input signal to the Powertrain Control Module
(PCM). The PCM interprets the sensor input signal to determine the crankshaft position. The PCM
then uses this information, along with other inputs, to determine injector sequence and ignition timing.

A tonewheel (targetwheel) is bolted to the engine crankshaft (1). This tonewheel has notches (2) on
the outer edge.

Fig. 444: Crankshaft Position Sensor

Courtesy of CHRYSLER GROUP, LLC

The sensor (1) is a hall effect device combined with an internal magnet. It is also sensitive to steel
within a certain distance from it.
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Fig. 445: Crankshaft Position Sensor Operation & Notches - 5.7L
Courtesy of CHRYSLER GROUP, LLC

The notches (3) cause a pulse to be generated when they pass under the sensor. The generated
pulses are the input signal to the PCM.

REMOVAL

3.6L

Fig. 446: Negative Battery Cable

Courtesy of CHRYSLER GROUP, LLC

1. Disconnect and isolate the negative battery cable (1).

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Fig. 447: Lower Splash Shield & Fasteners
Courtesy of CHRYSLER GROUP, LLC

2. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .

3. Remove the belly pan retainers (1) and remove the belly pan.

Fig. 448: Heat Shield

Courtesy of CHRYSLER GROUP, LLC

The crankshaft position (CKP) sensor is mounted into the right rear side of the cylinder block.
4. Push back the heat shield (1) from the crankshaft position (CKP) sensor.

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Fig. 449: Electrical Connector
Courtesy of CHRYSLER GROUP, LLC

5. Disconnect the electrical connector (1) from the crankshaft position (CKP) sensor.

Fig. 450: Sensor Mounting Bolt & Sensor

Courtesy of CHRYSLER GROUP, LLC

6. Remove the sensor mounting bolt (2).

7. Carefully twist the sensor (1) from the cylinder block.
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Fig. 451: O-Ring
Courtesy of CHRYSLER GROUP, LLC

8. The CKP sensor O-ring (1) can be reused if not damaged.

5.7L

The Crankshaft Position (CKP) sensor is located at the right-rear side of the engine block (1). It is
positioned and bolted into a machined hole in the engine block.

Fig. 452: Crankshaft Position Sensor Electrical Connector

Courtesy of CHRYSLER GROUP, LLC
1. Disconnect and isolate the negative battery cable.
2. Raise and support the vehicle.
3. Remove the starter motor Refer to STARTER, REMOVAL .
4. Disconnect the CKP sensor electrical connector (1).

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Fig. 453: Crankshaft Position Sensor Mounting Bolt
Courtesy of CHRYSLER GROUP, LLC

5. Remove the CKP sensor mounting bolt (1).

6. Using a slight twisting motion, remove the CKP sensor from the engine block.

Fig. 454: Crankshaft Position Sensor

Courtesy of CHRYSLER GROUP, LLC

7. Check the condition of the sensor O-ring (1) and replace if necessary.
INSTALLATION

3.6L

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Fig. 455: O-Ring
Courtesy of CHRYSLER GROUP, LLC

1. The crankshaft position (CKP) sensor O-ring (1) can be reused if not damaged.
2. Apply a small amount of engine oil to the sensor O-ring (1).

Fig. 456: Sensor Mounting Bolt & Sensor

Courtesy of CHRYSLER GROUP, LLC

3. Clean out the CKP sensor mounting bolt hole in the engine block.
4. Install the sensor (1) into the engine block with a slight rocking and twisting motion.
CAUTION: Before tightening the CKP sensor mounting bolt, be sure the sensor
is completely flush to the cylinder block. If the CKP sensor is not
flush, damage to the sensor mounting tang may result.

5. Install the mounting bolt (2) and tighten to 12 N.m (9 ft. lbs.).

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Fig. 457: Electrical Connector
Courtesy of CHRYSLER GROUP, LLC

6. Connect the CKP sensor electrical connector (1).

Fig. 458: Heat Shield

Courtesy of CHRYSLER GROUP, LLC

7. Position the heat shield (1) over the CKP sensor.

Fig. 459: Lower Splash Shield & Fasteners

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Courtesy of CHRYSLER GROUP, LLC

8. Position the belly pan and install the retainers (1).

9. Lower the vehicle.

Fig. 460: Negative Battery Cable

Courtesy of CHRYSLER GROUP, LLC

10. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

NOTE: The Cam/Crank Variation Relearn procedure must be performed using the scan
tool anytime there has been a repair/replacement made to a powertrain system,
for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or
components.
5.7L

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Fig. 461: Crankshaft Position Sensor
Courtesy of CHRYSLER GROUP, LLC

NOTE: Before installing the Crankshaft Position (CKP) sensor, check the condition of
the sensor O-ring (1) and replace if necessary.

1. Clean the machined hole in the engine block.

2. Apply a small amount of engine oil to the CKP sensor O-ring (1).
3. Install the CKP sensor into the engine block with a slight twisting motion.
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Fig. 462: Crankshaft Position Sensor Mounting Bolt
Courtesy of CHRYSLER GROUP, LLC

CAUTION: Before tightening the CKP sensor mounting bolt (1), be sure the
sensor is completely flush to the cylinder block. If sensor is not
flush, damage to the sensor mounting tang may result.

4. Install the CKP sensor mounting bolt (1) and tighten to 12 N.m (9 ft. lbs.).

Fig. 463: Crankshaft Position Sensor Electrical Connector

Courtesy of CHRYSLER GROUP, LLC

5. Connect the CKP sensor electrical connector (1).

6. Install the starter motor. Refer to STARTER, INSTALLATION .
7. Lower the vehicle.
8. Install the negative battery cable.

SENSOR, MANIFOLD AIR PRESSURE (MAP)

REMOVAL

3.6L

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Fig. 464: Negative Battery Cable
Courtesy of CHRYSLER GROUP, LLC

1. Disconnect and isolate the negative battery cable (1).

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Fig. 465: Engine Cover
Courtesy of CHRYSLER GROUP, LLC

2. Lift the engine cover retaining grommets off the ball studs and remove the engine cover (1).

Fig. 466: MAP Sensor Electrical Connector

Courtesy of CHRYSLER GROUP, LLC

3. Unlock and disconnect the electrical connector (1) from the MAP sensor.
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Fig. 467: Removing MAP Sensor
Courtesy of CHRYSLER GROUP, LLC

4. Rotate the MAP sensor 1/4 turn counterclockwise and pull the sensor straight up and out of the
upper intake manifold.

Fig. 468: O-Ring

Courtesy of CHRYSLER GROUP, LLC

5. The MAP sensor O-ring (1) can be reused if not damaged.

5.7L
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Fig. 469: MAP Sensor Location - 5.7L
Courtesy of CHRYSLER GROUP, LLC

The Manifold Absolute Pressure (MAP) sensor (3) is mounted into the top/rear of the intake manifold
(4) near the cowl/hood seal (1).

Fig. 470: 5.7L MAP Sensor R/I

Courtesy of CHRYSLER GROUP, LLC

1. Disconnect electrical connector at sensor by sliding release lock out (1). Press down on lock tab
(2) for removal.
2. Rotate sensor 1/4 turn counter-clockwise for removal.
3. Check condition of sensor o-ring.

INSTALLATION

3.6L

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Fig. 471: O-Ring
Courtesy of CHRYSLER GROUP, LLC

1. The manifold air pressure (MAP) sensor O-ring (1) can be reused if not damaged.
2. Apply a small amount of engine oil to the sensor O-ring (1).
Fig. 472: MAP Sensor And Rotate 1/4 Turn Clockwise
Courtesy of CHRYSLER GROUP, LLC

3. Install the MAP sensor (1) into the upper intake manifold and rotate 1/4 turn clockwise.

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Fig. 473: MAP Sensor Electrical Connector
Courtesy of CHRYSLER GROUP, LLC

4. Connect and lock the electrical connector (1) to the sensor.

Fig. 474: Engine Cover
Courtesy of CHRYSLER GROUP, LLC

5. Position the engine cover (1) and secure the retaining grommets onto the ball studs.

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Fig. 475: Negative Battery Cable
Courtesy of CHRYSLER GROUP, LLC

6. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

5.7L

Fig. 476: MAP Sensor Location - 5.7L

Courtesy of CHRYSLER GROUP, LLC

1. Clean MAP sensor mounting hole at intake manifold.

2. Check MAP sensor o-ring seal for cuts or tears.
3. Position sensor (3) into intake manifold.
4. Rotate sensor 1/4 turn clockwise for installation.
5. Connect electrical connector (2) to sensor (3).

SENSOR, OXYGEN

REMOVAL

3.6L

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Fig. 477: Right Upstream/Downstream Oxygen Sensors & Left Upstream/Downstream Oxygen
Sensors
Courtesy of CHRYSLER GROUP, LLC

The engine is equipped with four heated oxygen sensors:

The right upstream oxygen sensor (1) is referred to as the 1/1 sensor.
The right downstream oxygen sensor (2) is referred to as the 1/2 sensor.
The left upstream oxygen sensor (4) is referred to as the 2/1 sensor.
The left downstream oxygen sensor (3) is referred to as the 2/2 sensor.

WARNING: The exhaust pipes and catalytic converter become very hot during engine
operation. Allow the engine to cool before removing the oxygen sensor.

1. Disconnect and isolate the negative battery cable.

2. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
CAUTION: When disconnecting the oxygen sensor electrical connector, do not
pull directly on the wire going into the sensor. The sensor wiring can
be damaged resulting in sensor failure.

3. Disconnect the heated oxygen sensor electrical connector.

4. Remove the oxygen sensor.
5. Clean the exhaust pipe threads using an appropriate tap.

5.7L

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Fig. 478: O2S Sensors
Courtesy of CHRYSLER GROUP, LLC

UPSTREAM O2S SENSORS

1. Raise and support the vehicle.

WARNING: The exhaust pipes and catalytic converter become very hot during
engine operation. Allow the engine to cool before removing the
oxygen sensor.

CAUTION: When disconnecting the oxygen sensor electrical connector, do not

pull directly on the wire going into the sensor. The sensor wiring can
be damaged resulting in sensor failure.

2. Disconnect the O2S sensors (1, 2) electrical connectors.

3. Remove the left catalytic converter heat shield.
4. Using the appropriate oxygen sensor removal/installation tool, remove the O2S sensors.
5. Clean the threads in the exhaust pipes using an appropriate tap.

DOWNSTREAM O2S SENSORS

1. Raise and support the vehicle.
2. Support the transmission with a safety stand or suitable jack, remove the crossmember
retaining bolts and slightly lower the transmission to gain access to the O2S sensor electrical
connectors.

CAUTION: When disconnecting the oxygen sensor electrical connector, do not

pull directly on the wire going into the sensor. The sensor wiring can
be damaged resulting in sensor failure.

3. Disconnect the O2S sensors (3, 4) electrical connectors.

4. Using the appropriate oxygen sensor removal/installation tool, remove the O2S sensors.
5. Clean the threads in the catalytic converters using an appropriate tap.

INSTALLATION

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3.6L

Fig. 479: Right Upstream/Downstream Oxygen Sensors & Left Upstream/Downstream Oxygen
Sensors
Courtesy of CHRYSLER GROUP, LLC

The engine is equipped with four heated oxygen sensors:

1. If reinstalling the original oxygen sensor, coat the sensor threads with an anti-seize compound
such as Loctite 771- 64 or equivalent. New sensors have compound on the threads and do not
require an additional coating. Do Not add any additional anti-seize compound to the
threads of a new oxygen sensor.
2. Install the oxygen sensor and tighten to 50 N.m (37 ft. lbs.).

CAUTION: Never apply any type of grease to the oxygen sensor electrical
connector, or attempt any repair of the sensor wiring harness.

3. Connect the heated oxygen sensor electrical connector.

4. Lower the vehicle.
5. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

5.7L

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Fig. 480: O2S Sensors
Courtesy of CHRYSLER GROUP, LLC

DOWNSTREAM O2S SENSORS

Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. Do
not add any additional anti-seize compound to threads of a new oxygen sensor.

1. Using the appropriate oxygen sensor removal/installation tool, install the O2S sensors (3, 4) and
tighten to 41 N.m (30 ft. lbs.).
2. Connect the O2S sensors electrical connectors.
3. Raise the transmission and install the crossmember to frame bolts and tighten to 68 N.m (50 ft.
lbs.), remove the safety stand or jack.
4. Lower the vehicle.
UPSTREAM O2S SENSORS

Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. Do
not add any additional anti-seize compound to threads of a new oxygen sensor.

1. Using the appropriate oxygen sensor removal/installation tool, install the O2S sensors (1, 2) and
tighten to 41 N.m (30 ft. lbs.).
2. Install the left catalytic converter heat shield.
3. Connect the O2S sensors electrical connectors.
4. Lower the vehicle.

SOLENOID, SHORT RUNNER VALVE

OPERATION

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The SRV system operates under WOT conditions above 5000 RPM to maximize engine performance.
When actuated by the PCM, the SRV solenoid energizes, allowing mechanical linkage to redirect the
intake air flow to six short runners. The PCM looks for a current spike when actuating the solenoid. If
the spike is not present, the PCM sets the DTC.

REMOVAL

REMOVAL - 5.7L

Fig. 481: Negative Battery Cable

Courtesy of CHRYSLER GROUP, LLC

1. Disconnect the negative battery cable (1).

Fig. 482: Intake Manifold Retaining Bolt Removal & Tightening Sequence

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC

2. Remove the intake manifold and throttle body as an assembly Refer to MANIFOLD, INTAKE,
REMOVAL or MANIFOLD, INTAKE, REMOVAL or MANIFOLD, INTAKE, REMOVAL, 5.7L or
MANIFOLD, INTAKE, REMOVAL .

Fig. 483: Short Runner Valve Actuator Retaining Bolts

Courtesy of CHRYSLER GROUP, LLC

3. Remove the short runner valve actuator retaining bolts (1) and remove valve.
Fig. 484: Short Runner Valve Actuator Rubber O-Ring Seal

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Courtesy of CHRYSLER GROUP, LLC

4. Remove and discard the short runner valve actuator rubber O-ring seal (1).

INSTALLATION

INSTALLATION - 5.7L

Fig. 485: Short Runner Valve Actuator Rubber O-Ring Seal

Courtesy of CHRYSLER GROUP, LLC

1. Install a new short runner valve actuator rubber O-ring seal (1).
Fig. 486: Short Runner Valve Actuator Retaining Bolts

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Courtesy of CHRYSLER GROUP, LLC

2. Position the short runner valve actuator, install the retaining bolts (1) and tighten to 5 N.m (44 in.
lb.).

Fig. 487: Intake Manifold Retaining Bolt Removal & Tightening Sequence
Courtesy of CHRYSLER GROUP, LLC

3. Install the intake manifold and throttle body as an assembly. Refer to MANIFOLD, INTAKE,
INSTALLATION or MANIFOLD, INTAKE, INSTALLATION or MANIFOLD, INTAKE,
INSTALLATION, 5.7L or MANIFOLD, INTAKE, INSTALLATION .
Fig. 488: Negative Battery Cable

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC

4. Connect the negative battery cable (1).

THROTTLE BODY

REMOVAL

3.6L

Fig. 489: Negative Battery Cable

Courtesy of CHRYSLER GROUP, LLC

1. Disconnect and isolate the negative battery cable (1).

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Fig. 490: Engine Cover
Courtesy of CHRYSLER GROUP, LLC

2. Lift the engine cover retaining grommets off the ball studs and remove the engine cover (1).

Fig. 491: Inlet Air Temperature (IAT) Sensor Electrical Connector, Air Inlet Hose
Assembly & Fasteners
Courtesy of CHRYSLER GROUP, LLC

3. Disconnect the electrical connector (1) from the Inlet Air Temperature (IAT) sensor.
4. Loosen the clamp (2) at the throttle body.
5. Loosen the clamp (3) at the air cleaner housing.
6. Lift the air inlet hose assembly retaining grommet off the ball stud (4).
7. Remove the air inlet hose assembly (5).
CAUTION: Never have the ignition key in the ON position when checking the
throttle body shaft for a binding condition. This may set DTC's.

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Fig. 492: Electrical Connector, Electronic Throttle Control (ETC), Clip & Mounting Bolts
Courtesy of CHRYSLER GROUP, LLC

8. Disconnect the electrical connector (1) from the Electronic Throttle Control (ETC) (2) and
unfasten the ETC harness from the clip (4) on the throttle body.
9. Remove four throttle body mounting bolts (3).
10. Remove the throttle body from the upper intake manifold.
11. Check the condition of the throttle body-to-intake manifold seal. The seal can be reused if not
damaged.

5.7L
Fig. 493: Removing/Installing Throttle Body - 5.7L

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC

CAUTION: Do not use spray (carb) cleaners on any part of the throttle body. Do not
apply silicone lubricants to any part of the throttle body.

1. Remove rubber air duct at front of throttle body.

2. Disconnect electrical connector (3) at throttle body (1).
3. Remove four throttle body mounting bolts (2).
4. Remove throttle body from intake manifold.

Fig. 494: Locating Throttle Body O-Ring AT Intake Manifold - 5.7L

Courtesy of CHRYSLER GROUP, LLC

5. Check condition of throttle body o-ring (2) at front of intake manifold (1).
INSTALLATION

3.6L

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Fig. 495: Throttle Body-To-Intake Manifold Seal
Courtesy of CHRYSLER GROUP, LLC

1. Check the condition of the throttle body-to-intake manifold seal (1). The seal can be reused if
not damaged.
2. Clean the mating surfaces of the throttle body and intake manifold.

Fig. 496: Electrical Connector, Electronic Throttle Control (ETC), Clip & Mounting Bolts
Courtesy of CHRYSLER GROUP, LLC

3. Position the throttle body (2) to the intake manifold.

4. Install the throttle body mounting bolts (3) and tighten in a crisscross pattern sequence to 6 N.m
(53 in. lbs.).
5. Connect the electrical connector (1) to the Electronic Throttle Control (ETC) (2) and secure the
ETC harness to the clip (4) on the throttle body.

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Fig. 497: Inlet Air Temperature (IAT) Sensor Electrical Connector, Air Inlet Hose
Assembly & Fasteners
Courtesy of CHRYSLER GROUP, LLC

6. Position the air inlet hose assembly (5) onto the throttle body and the air cleaner housing.
7. Secure the air inlet hose assembly retaining grommet onto the ball stud (4).
8. Tighten the clamp at the air cleaner housing (3) to 5 N.m (44 in. lbs.).
9. Tighten the clamp (2) at the throttle body to 5 N.m (44 in. lbs.).
10. Connect the Inlet Air Temperature (IAT) sensor electrical connector (1).
cardiagn.com
Fig. 498: Engine Cover
Courtesy of CHRYSLER GROUP, LLC

11. Position the engine cover (1) and secure the retaining grommets onto the ball studs.

Fig. 499: Negative Battery Cable

Courtesy of CHRYSLER GROUP, LLC

12. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

5.7L
cardiagn.com
Fig. 500: Locating Throttle Body O-Ring AT Intake Manifold - 5.7L
Courtesy of CHRYSLER GROUP, LLC

1. Clean and check condition of throttle body-to-intake manifold o-ring (2).

2. Clean mating surfaces of throttle body and intake manifold (1).

Fig. 501: Removing/Installing Throttle Body - 5.7L

Courtesy of CHRYSLER GROUP, LLC

CAUTION: Do not use spray (carb) cleaners on any part of the throttle body. Do
not apply silicone lubricants to any part of the throttle body.

3. Install throttle body to intake manifold by positioning throttle body to manifold alignment pins.
4. Install and tighten four mounting bolts (2). Refer to TORQUE .
5. Install electrical connector (3).
6. Install rubber air hose to throttle body.
7. A Scan Tool may be used to learn electrical parameters. Go to the Miscellaneous menu, and
then select ETC Relearn. If the relearn is not performed, a Diagnostic Trouble Code (DTC) will
be set. If necessary, use a scan tool to erase any Diagnostic Trouble Codes (DTC's) from PCM.

VALVE, SHORT RUNNER

DESCRIPTION

The intake manifold features a dual shaft Short Runner Valve (SRV) system to maximize both low
end torque and peak power. The SRV is bolted to the rear of the intake manifold and can be service
separately from the manifold.

cardiagn.com
The SRV system operates under Wide Open Throttle conditions to maximize engine performance.
When activated by the PCM, the SRV actuates a mechanical linkage to redirect the intake air flow to
eight short runners. The PCM looks for a signal feedback when the actuator is activated. If the signal
feedback is not present, the PCM sets the DTC.

REMOVAL

REMOVAL
cardiagn.com
Fig. 502: Negative Battery Cable
Courtesy of CHRYSLER GROUP, LLC

1. Disconnect the negative battery cable (1).

Fig. 503: Intake Manifold And Throttle Body

Courtesy of CHRYSLER GROUP, LLC
2. Remove the intake manifold and throttle body as an assembly. Refer to MANIFOLD, INTAKE,
REMOVAL or MANIFOLD, INTAKE, REMOVAL or MANIFOLD, INTAKE, REMOVAL, 5.7L or
MANIFOLD, INTAKE, REMOVAL .

cardiagn.com
Fig. 504: Short Runner Valve (SRV) Actuator Retaining Bolts & SRV Actuator
Courtesy of CHRYSLER GROUP, LLC

3. Remove the Short Runner Valve (SRV) actuator retaining bolts (1) and remove the SRV
actuator (2).

Fig. 505: Rubber O-Ring Seal

Courtesy of CHRYSLER GROUP, LLC

NOTE: When the SRV actuator is removed, a new rubber O-ring seal must be
installed. The old O-ring cannot be reused.
4. Remove and discard the SRV actuator rubber O-ring seal (1).

INSTALLATION

cardiagn.com
Fig. 506: Rubber O-Ring Seal
Courtesy of CHRYSLER GROUP, LLC

NOTE: When the SRV actuator is removed, a new rubber O-ring seal must be installed.
The old O-ring cannot be reused.

1. Install a new SRV actuator rubber O-ring seal (1).

Fig. 507: Short Runner Valve (SRV) Actuator Retaining Bolts & SRV Actuator
Courtesy of CHRYSLER GROUP, LLC
2. Position the SRV actuator (2), install the retaining bolts (1) and tighten to 5 N.m (44 in. lb.).

cardiagn.com
Fig. 508: Intake Manifold And Throttle Body
Courtesy of CHRYSLER GROUP, LLC

4. Connect the negative battery cable (1).

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