ENGINE Fuel System - Ram Pickup

2014 RAM 3500 HD Laramie
2014 ENGINE Fuel System - Ram Pickup
2014 ENGINE
Fuel System - Ram Pickup
FUEL DELIVERY, GAS

STANDARD PROCEDURE
DRAINING FUEL TANK
CONVENTIONAL PROCEDURE
Fig. 1: Fuel Supply Line Quick Connect Fitting At Fuel Rail

Courtesy of CHRYSLER GROUP, LLC
WARNING: The fuel system may be under constant fuel pressure even with the
engine off. This pressure must be released before servicing the fuel tank.
Due to a one-way check valve installed into the fuel fill fitting at the tank, the tank cannot be drained at the fuel
fill cap.
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 FITTING, QUICK CONNECT -
STANDARD PROCEDURE .
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Fig. 2: Fuel Line Adapters

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 Decay Tool, Fuel 8978A to the fuel supply line.
Route the opposite end of this hose to an OSHA approved fuel storage tank such as the John Dow Gas
Caddy 320-FC-P30-A or equivalent.
4. Using a diagnostic scan tool, activate the fuel pump until the fuel tank has been evacuated.
ALTERNATIVE PROCEDURE
Fig. 3: Battery
Thursday, November 16, 2017 19:32:21 Page 2

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. Perform the Fuel System Pressure Release procedure. Refer to FUEL SYSTEM PRESSURE
RELEASE .
2. Disconnect and isolate the negative battery cable (1).
3. Raise and support the vehicle.
4. Remove the fuel tank. Refer to TANK, FUEL, REMOVAL .
Fig. 4: Fuel Pump Module

5. Remove the fuel pump module (1). Refer to MODULE, FUEL PUMP, REMOVAL .
6. Position a 3/8" hose into the fuel pump module opening of the fuel tank.
7. Attach the opposite end of this hose to the Fuel Chief Gas Caddy 320-FC-P30-A or an OSHA approved
gas caddy.
8. Using the gas caddy, evacuate the fuel tank.
FUEL SYSTEM PRESSURE RELEASE
Use this procedure whether or not the fuel rail is equipped with a fuel pressure test port.
1. Remove the fuel fill cap.

2. Remove the Power Distribution Center (PDC) cover from the PDC housing base.
3. Remove fuse F70 from the PDC.
4. Start and run the engine until it stalls.
5. Attempt restarting the engine until it will no longer start.
6. Turn the ignition key to the OFF position.


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.
NOTE: Excessive fuel spillage onto the gaskets can cause gaskets to expand and
dislodge from gasket groove.
7. Place a rag or towel below the fuel line quick-connect fitting at the fuel rail.
8. Disconnect the fuel line quick-connect fitting at the fuel rail (1) and plug with a shipping cap to prevent
spillage. Refer to FITTING, QUICK CONNECT - STANDARD PROCEDURE .
NOTE: One or more Diagnostic Trouble Codes (DTC's) may have been stored in the
PCM memory due to disconnecting fuel pump module circuit. A diagnostic scan
tool must be used to erase a DTC.
SPECIFICATIONS
FUEL SYSTEM PRESSURE-GAS
58 psi +/- 2 psi
SPECIFICATIONS - CNG
Liquid Gas Fuel Pressure at Fuel Rail 58 psi +/- 2 psi

Compressed Natural Gas Fuel Pressure to Regulator 230 - 4, 200 psi +/- Temperature at the Tanks
Compressed Natural Gas Fuel Pressure Internal
230 psi
Regulator

Compressed Natural Gas Fuel Pressure after

163 psi
Regulator
Compressed Natural Gas Fuel Pressure Relief
4, 800 - 5000 psi
Device
TORQUE
DESCRIPTION N.m Ft. lbs. In. lbs.

Accelerator Pedal Bracket 12 - 105
Mounting
Accelerator Pedal Position 3 - 30
Sensor Bracket-to-Battery Tray
Bolts
Crankshaft Position Sensor - 12 - 105 (+/-20)
5.7L/6.4L
Camshaft Position Sensor - 12 9 105 (+/-) 20
5.7L/6.4L
EVAP Canister- to-Bracket Nuts 8.5 - 75
EVAP Canister-to-Frame Bolts 34 25
Fuel Filler Hose Clamp at Tank 3 - 30
Fuel Filler Housing-to-Body 2 - 17
Screws
Fuel Rail Mounting Bolts - 11 - 100
5.7L/6.4L
Fuel Tank Mounting Straps 41 30 -
Fuel Tank Mounting Bolts - 52
55 41 -
Gallon Tank
PCM-to-Mounting Bracket 4 - 35
Mounting Screws
Throttle Body Mounting Bolts - 5.6 - 50
5.7L/6.4L
Oxygen Sensors 41 30 -
Ignition Coil Mounting Bolts 11 - 100
SPECIAL TOOLS
SPECIAL TOOLS

9340 - SAE Fuel Pump Lock Ring

Wrench
(Originally Shipped In Kit Number(s)
9327, 9327CC, 9397, 9575.)
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, 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 FITTING, QUICK CONNECT - STANDARD PROCEDURE .
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.
STANDARD PROCEDURE
STANDARD PROCEDURE - QUICK-CONNECT FITTINGS
Some quick-connect fittings require the use of a special tool for disconnection and removal.

NOTE: Care must be used when separating fittings. Over-flexing may cause the tube to
become deformed or damaged.
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: On vehicles equipped with gasoline engines, 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.

breakage.
REDUNDANT LATCH SINGLE BUTTON TYPE FITTING:

Fig. 6: Redundant Latch & Push Button

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

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:
Fig. 8: Single Button Fitting

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.
Fig. 9: Ouick-Connect Fitting Latches


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: 2-Button Type Fitting

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. 11: Pinch Type Quick-Connect Fitting

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.
SINGLE TAB TYPE FITTING
Fig. 12: Single-Tab Type Fitting


This type of quick-connect fitting (2) is equipped with a single pull tab (1). The tab is removable. After tab is
removed, the quick-connect fitting (2) can be separated from the fuel system component (4). Special tools are
not required for removal.
1. Press release tab (3) on side of fitting to release pull tab (1).
NOTE: If release tab is not pressed prior to releasing pull tab, pull tab will be
damaged.
Fig. 13: Disconnecting Single-Tab Type Fitting

2. While pressing the release tab on the side of the quick-connect fitting use a screwdriver (2) to pry up the
pull tab (1).
3. Raise the pull tab (1) until it separates from the quick-connect fitting (3).
4. Remove the quick-connect fitting (3) from the fuel system component.
TWO TAB TYPE FITTING

Fig. 14: Typical Two-Tab Type Quick-Connect Fitting

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.
PLASTIC RETAINER RING TYPE FITTING
Fig. 15: Plastic Retainer Ring Type Fitting


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
Fig. 16: Latch Clip Type 1

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.

Fig. 17: Fuel Line Disconnection Using Special Tool

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 Type 2

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.

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

Fig. 20: Wing Type Fitting

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.
SENDING UNIT AND SENSOR, FUEL LEVEL
DESCRIPTION
DESCRIPTION
The fuel gauge sending unit (fuel level sensor) is attached to the fuel pump module. The sending unit consists of
a float, an arm, and a variable resistor track (card).
The sensor is non-serviceable. If replacement is necessary, the fuel pump module assembly must be replaced.
REGULATOR, FUEL PRESSURE
DESCRIPTION
DESCRIPTION
The fuel pressure regulator is located in the fuel pump module assembly and is non-serviceable.
MODULE, FUEL PUMP, ELECTRIC
DESCRIPTION
DESCRIPTION
The electric fuel pump is located inside of the fuel pump module. A 12 volt, permanent magnet, electric motor
powers the fuel pump. The electric fuel pump is not a separate, serviceable component.
OPERATION
ELECTRIC FUEL PUMP
Voltage to operate the electric pump is supplied through the fuel pump relay.
Fuel is drawn in through a filter at the bottom of the module and pushed through the electric motor gearset to
the pump outlet.
Check Valve Operation: The bottom section of the fuel pump module contains a one-way check valve to
prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not
operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the
vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain
in fuel supply line between the check valve and fuel injectors.Fuel pressure that has dropped to 0 psi on a
cooled down vehicle (engine off) is a normal condition.
The electric fuel pump is not a separate, serviceable component.

MODULE, FUEL PUMP
DESCRIPTION
FUEL PUMP MODULE
The fuel pump module assembly is located on the top of the fuel tank . The complete assembly contains the
following components:
A combination fuel filter/fuel pressure regulator

A separate fuel pick-up, or inlet filter
An electric fuel pump
A lockring to retain pump module to tank
A soft gasket between tank flange and module
A fuel gauge sending unit (fuel level sensor)
Fuel line connection
The fuel gauge sending unit may be serviced separately. If the electrical fuel pump, primary inlet filter, fuel
filter or fuel pressure regulator require service, the fuel pump module must be replaced.
OPERATION
OPERATION
Refer to MODULE, FUEL PUMP, ELECTRIC, MODULE, FUEL PUMP, REGULATOR, FUEL
PRESSURE and SENDING UNIT AND SENSOR, FUEL LEVEL .
REMOVAL
REMOVAL

Fig. 21: Battery

WARNING: The fuel system may be under a constant pressure (even with the engine
off). Before servicing the fuel pump module, the fuel system pressure
must be released.
Fig. 22: Fuel Pump Module Location

NOTE: Prior to removing the fuel pump module, use compressed air to remove
any accumulated dirt and debris from around fuel tank opening.
CAUTION: An indexing arrow is located on top of the main fuel pump module to
clock it's position into the fuel tank, note it's location for reassembly.
4. Position the lock ring remover/installer (special tool #9340, SAE Fuel Pump Lock Ring Wrench) (3) into
the notches on the outside edge of the lock ring (5).
5. Install a 1/2 inch drive breaker bar (1) into the lock ring remover/installer (special tool #9340, SAE Fuel
Pump Lock Ring Wrench) (3).
6. Rotate the breaker bar counterclockwise and remove the lock ring.
CAUTION: Whenever the fuel pump module is serviced, the rubber O-ring seal

must be replaced.
7. Remove the fuel pump module (4) from the fuel tank. Be careful not to bend float arm during removal.
8. Remove and discard the rubber O-ring seal.
INSTALLATION
INSTALLATION

CAUTION: An indexing arrow is located on top of the main 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.
1. Using a new rubber O-ring seal, position the fuel pump module into the fuel tank opening.
2. Position the lock ring (5) over top of the fuel pump module.
3. Rotate the fuel pump module until the embossed alignment arrow points to the center alignment mark or
the same position as noted during removal. This step must be performed to prevent the float from
contacting the side of the fuel tank.
4. Install the lock ring remover/installer (special tool #9340, SAE Fuel Pump Lock Ring Wrench) (3) into
6. Rotate the breaker bar clockwise until all seven notches of the lock ring have engaged.
7. Install the fuel tank. Refer to TANK, FUEL, INSTALLATION .

8. Connect the fuel line quick-connect fitting at the fuel rail (1).
Fig. 25: Battery

9. Connect the negative battery cable (1).

10. Fill the fuel tank.
11. Start the engine and check for leaks at all fuel tank connections.
RAIL, FUEL
DESCRIPTION

DESCRIPTION
The fuel injector rail is used to mount the fuel injectors to the engine.
OPERATION
OPERATION
High pressure from the fuel pump is routed to the fuel rail. The fuel rail then supplies the necessary fuel to each
individual fuel injector.
A quick-connect fitting with a safety latch clip is used to attach the fuel line to the fuel rail.
The fuel rail is not repairable.
CAUTION: The left and right sections of the fuel rail are connected with either a
flexible connecting hose, or joints. Do not attempt to separate the rail
halves at these connecting hose or joints. Due to the design of the
connecting hose or joint, it does not use any clamps. Never attempt to
install a clamping device of any kind to the hose or joint. When removing
the fuel rail assembly for any reason, be careful not to bend or kink the
connecting hose or joint.
REMOVAL
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.
2. Remove the negative battery cable.

Fig. 26: Engine Cover, Clean Air Hose, Intake Air Temperature (IAT) Sensor Electrical Connector
& Air Cleaner Housing
3. Disconnect the IAT sensor electrical connector (3).

4. Remove the clean air tube (2) from the air cleaner housing (4) and the throttle body.
Fig. 27: Engine Cover Mounts

NOTE: The front grommets (1, 3) are a ball stud type mount and the rear
grommets (2) are a sliding peg design.

Fig. 28: Engine Cover & Grommets

5. Lift up the front of the engine cover (1) and separate the engine cover front grommets (2) from the ball
studs on the intake manifold.
Fig. 29: Engine Cover Pegs & Grommets

6. Slightly raise the front of the engine cover and slide forward to remove the rear engine cover pegs (2)

from the grommets (1) located on the rear of the intake manifold and remove the engine cover.
Fig. 30: Removing/Installing Fuel Injector Connector

CAUTION: The left and right fuel rails are replaced as an assembly. Do not
attempt to separate the fuel rail halves at the connector tube. Due to
the 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 the fuel rail assembly for any reason, be careful
not to bend or kink the connector tube.
NOTE: The factory fuel injection electrical harness is numerically tagged (INJ 1,
INJ 2, etc.) for injector position identification. If the electrical harness is
not tagged, note the injector position before electrical harness removal.
7. Disconnect the electrical connectors at all eight fuel injectors. Push the red colored slider away from the
injector (1) while pushing slider, depress tab (2) and remove the electrical connector (3) from the injector.

Fig. 31: PCV Hose & Fuel Line Quick Connect Fitting
8. Disconnect the PCV hose (1) and position aside to gain access to the fuel rail.
9. Disconnect the fuel line quick connect fitting (2) at the fuel rail. Refer to FITTING, QUICK
CONNECT - STANDARD PROCEDURE .
10. Disconnect the make up air hose (3) and position aside to gain access to the fuel rail.
11. Remove the four fuel rail mounting bolts (4) from both the left and right fuel rails.
12. Using a side to side motion, gently rock the left fuel rail while pulling up until all four left side fuel
injectors just start to clear the machined holes in the intake manifold.
13. Using a side to side motion, gently rock the right fuel rail while pulling up until all four right side fuel
NOTE: Make sure the O-rings are still attached to the fuel injectors during
removal.
14. Remove the left and right fuel rails (with injectors attached) as an assembly from the engine.
NOTE: If the same fuel injectors are to be reinstalled, install new O-rings.
15. If the fuel injectors are to be removed from the fuel rail. Refer to INJECTOR(S), FUEL, REMOVAL .
6.4L

Fig. 32: Clamp, Air Intake Tube & Breather Hose


4. Disconnect the breather hose from the air intake tube (2).
5. Remove the air intake tube from the air cleaner housing and the throttle body.
Fig. 33: Engine Cover & Grommets

NOTE: The front grommets (1, 3) are a ball stud type mount and the rear
grommets (2) are a sliding peg design.

6. Lift up the front of the engine cover (1) and separate the engine cover front grommets (2) from the ball
studs on the intake manifold.
7. Slightly raise the front of the engine cover and slide forward to remove the rear engine cover pegs (2)
from the grommets (1) located on the rear of the intake manifold and remove the engine cover.


Fig. 35: Injectors Harness Connectors & Ignition Coil Harness Connectors
NOTE: Left side shown in illustration. Right side similar.
8. Disconnect the electrical connectors at all eight fuel injectors (1). Push the red colored slider away from
the injector while pushing slider, depress tab and remove the electrical connector from the injector.
9. Disconnect the fuel line quick connect fitting (2) at the fuel rail. Refer to FITTING, QUICK
removal.
INSTALLATION

5.7
Fig. 36: Injector Retaining Clip

1. If the fuel injectors (3) are to be installed into the fuel rail (4)
Refer to INJECTOR(S), FUEL, INSTALLATION .
2. Clean out the fuel injector machined holes in the intake manifold.
3. Apply a small amount of engine oil to each fuel injector O-ring. This will help in the fuel rail installation.
4. Position the fuel rail assembly while aligning the injectors into the machined holes in the intake manifold.
5. Guide each injector into the intake manifold using care not to tear the injector O-rings.
6. Using a side to side motion, gently rock the left fuel rail while pushing down until all four left side fuel
injectors have completely seated into the machined holes in the intake manifold.

7. Install the four fuel rail mounting bolts (4). Tighten to 11 N.m (97 in. lbs.).
8. Connect the breather hose (3).
9. Connect the fuel line quick connect fitting to the fuel rail (2). Refer to FITTING, QUICK CONNECT -
10. Connect the PCV hose (1).


11. Connect the electrical connectors to all eight fuel injectors. Push the connector onto the injector (1) and
then push and lock the red colored slider (2). Verify the connector is locked to the injector by lightly
tugging on the connector.
Fig. 39: Engine Cover, Clean Air Hose, Intake Air Temperature (IAT) Sensor Electrical Connector
& Air Cleaner Housing

12. Install the engine cover (1).

13. Install the clean air tube (2) and air cleaner housing cover assembly (4) onto the throttle body.
14. Connect the IAT sensor electrical connector (3).
15. Connect the battery negative cable.
16. Start the engine and check for leaks.
6.4L

2. Clean out the fuel injector machined holes in the intake manifold.
3. Apply a small amount of engine oil to each fuel injector O-ring. This will help in the fuel rail installation.
4. Position the fuel rail assembly while aligning the injectors into the machined holes in the intake manifold.

7. Install the four fuel rail mounting bolts (4). Tighten to 11 N.m (97 in. lbs.).
8. Connect the fuel line quick connect fitting to the fuel rail (2). Refer to FITTING, QUICK CONNECT -

Fig. 42: Fuel Injector Electrical Connectors


NOTE: Right side shown in illustration. Left side similar.
9. Connect the electrical connectors to all eight fuel injectors (1). Push the connector onto the injector and
then push and lock the red colored slider. Verify the connector is locked to the injector by lightly tugging
on the connector.
10. Install the engine cover (1).
Fig. 43: Clamp, Air Intake Tube & Breather Hose

11. Install the air intake tube (2) onto the throttle body.
12. Install the breather tube (3).
13. Connect the IAT sensor electrical connector.
TANK, FUEL
REMOVAL
REMOVAL

Fig. 44: Battery

must be released.
Fig. 45: Top Of Fuel Tank

3. Raise and support vehicle.

4. Perform the fuel tank draining procedure. Refer to DRAINING FUEL TANK .
5. Disconnect the electrical connector from ESIM switch (4).
6. Disconnect the quick-connect fitting at the front of the fuel tank (10).
7. Disconnect the quick-connect fitting (8) at the rear of the fuel tank.
8. Loosen the fill hose retaining clamp (9) at the rear of the fuel tank and disconnect the fill hose.
9. Using a suitable hydraulic jack with a fuel tank adapter, support the fuel tank.
Fig. 46: Fuel Tank Mounting

10. Remove the two fuel tank support strap retaining nuts (5) and remove both fuel tank support straps (4).
11. Carefully lower the fuel tank a few inches and disconnect the fuel pump module electrical connector.
12. Disconnect the fuel line quick-connect fitting at the fuel pump module.
13. Lower the fuel tank and remove from hydraulic jack.
14. If fuel pump module removal is necessary. Refer to MODULE, FUEL PUMP, REMOVAL .
INSTALLATION
INSTALLATION


1. If fuel pump module installation is necessary. Refer to MODULE, FUEL PUMP, INSTALLATION .
2. Secure the fuel tank onto a suitable hydraulic jack with a fuel tank adapter.
3. Raise and position the fuel tank leaving room to make the connections at the top of the fuel tank.
4. Connect the fuel supply line (6) to the fuel pump module.
5. Connect the electrical connector (5) to the fuel pump module.


6. Raise the fuel tank (1) until snug to the body.

7. Install the fuel tank straps (4).
8. Install the strap nuts (5) and tighten to 41 N.m (30 ft. lbs.).
9. Remove the hydraulic jack.


10. Connect the electrical connector to the ESIM switch (4).

11. Connect the quick-connect fitting at the front of the fuel tank (10).
12. Connect the quick-connect fitting (8) at the rear of the fuel tank.
13. Connect the fill hose (7) at the rear of the fuel tank and securely tighten the fill hose retaining clamp (9).

Fig. 51: Battery


TUBE(S), FUEL
DESCRIPTION
DESCRIPTION
Also, refer to FITTING, QUICK CONNECT - STANDARD PROCEDURE.
off). Before servicing any fuel system hoses, fittings, lines, or most
components, fuel system pressure must be released. Refer to FUEL
SYSTEM PRESSURE RELEASE .
The lines/tubes/hoses used on fuel injected vehicles are of a special construction. This is due to the higher fuel
pressures and the possibility of contaminated fuel in this system. If it is necessary to replace these
lines/tubes/hoses, only those marked EFM/EFI may be used.
If equipped: The hose clamps used to secure rubber hoses on fuel injected vehicles are of a special rolled edge
construction. This construction is used to prevent the edge of the clamp from cutting into the hose. Only these
rolled edge type clamps may be used in this system. All other types of clamps may cut into the hoses and cause
high-pressure fuel leaks.

Use new original equipment type hose clamps.
FUEL INJECTION, GAS

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 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.
INJECTOR(S), FUEL
DESCRIPTION
DESCRIPTION
Fig. 52: Fuel Injector

1 - FUEL INJECTOR

2 - NOZZLE
3 - TOP (FUEL ENTRY)
An individual fuel injector (1) is used for each individual cylinder.
OPERATION
OPERATION

The fuel injectors (1) are electrical solenoids. The injector contains a pintle that closes off an orifice at the
nozzle end. When electric current is supplied to the injector, the armature and needle move a short distance
against a spring, allowing fuel to flow out the orifice. Because the fuel is under high pressure, a fine spray is
developed in the shape of a pencil stream. The spraying action atomizes the fuel, adding it to the air entering the
combustion chamber.
The top (fuel entry) end of the injector (3) is attached into an opening on the fuel rail.
The nozzle (outlet) ends of the injectors (2) are positioned into openings in the intake manifold just above the
intake valve ports of the cylinder head.
The injectors are energized individually in a sequential order by the Powertrain Control Module (PCM). The
PCM will adjust injector pulse width by switching the ground path to each individual injector on and off.
Injector pulse width is the period of time that the injector is energized. The PCM will adjust injector pulse width
based on various inputs it receives.
Battery voltage is supplied to the injectors through the ASD relay.
The PCM determines injector pulse width based on various inputs.
REMOVAL
5.7L/6.4L


1 - PLIERS
2 - INJECTOR CLIP
3 - FUEL INJECTOR - TYPICAL
4 - FUEL RAIL - TYPICAL
1. Remove the fuel rail assembly. Refer to RAIL, FUEL, REMOVAL .

2. Using suitable pliers (1), remove the fuel injector retaining clip (2).
3. Remove the fuel injector (3) from the fuel rail (4) using a side to side motion while pulling the injector
out of the fuel rail assembly.
INSTALLATION
5.7L/6.4L


1 - PLIERS
2 - INJECTOR CLIP
NOTE: If the same fuel injector is to be reinstalled, install new O-rings.
NOTE: Apply a small amount of clean engine oil to each injector O-ring. This will aid in
the installation.
1. Install the fuel injector (3) into the fuel rail (4) using a side to side motion while pushing injector into the
fuel rail assembly.
2. Using suitable pliers (1), install the fuel injector retaining clip (2).
3. Install the fuel rail assembly. Refer to RAIL, FUEL, INSTALLATION .
4. Start the engine and check for fuel leaks.
PEDAL, ACCELERATOR
REMOVAL
REMOVAL
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.
Fig. 56: Accelerator Pedal Position Sensor (APPS)

1. Disconnect the 6-way electrical connector at the APPS (1).

2. Remove the upper accelerator pedal mounting bolt (2).
3. Remove the lower accelerator pedal mounting bolt (3).
4. Remove the accelerator pedal assembly from the vehicle.
INSTALLATION
INSTALLATION



1. Position the accelerator pedal assembly on the pedal sled.

2. Install the lower accelerator pedal mounting bolt (3) and tighten to 7 N.m (5 ft. lbs.).
3. Install the upper accelerator pedal mounting bolt (2) 7 N.m (5 ft. lbs.).
4. Connect the 6-way electrical connector at the APPS (1).
5. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's).
RELAY, FUEL PUMP
DESCRIPTION
DESCRIPTION
A separate fuel pump relay is no longer used. A circuit within the Power Distribution Center (PDC) is
used to control the electric fuel pump located within the fuel pump module. The PDC is located near the
battery.
OPERATION
OPERATION
The Powertrain Control Module (PCM) energizes the electric fuel pump through the fuel pump relay. The fuel
pump relay is energized by first applying battery voltage to it when the ignition key is turned ON, and then
applying a ground signal to the relay from the PCM.
Whenever the ignition key is turned ON, the electric fuel pump will operate. But, the PCM will shut-down the
ground circuit to the fuel pump relay in approximately 1-3 seconds unless the engine is operating or the starter
motor is engaged.

SENSOR, ACCELERATOR PEDAL POSITION
DESCRIPTION
DESCRIPTION

1 - APPS
2 - APPS 6-Way Electrical Connector
3 - Accelerator Pedal
4 - Mounting Bolts/Nuts
The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator
pedal assembly (3).
OPERATION
OPERATION
The Accelerator Pedal Position Sensor (APPS) provides the Powertrain Control Module (PCM) with two DC
voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals
will be half the voltage of the other signal.
REMOVAL
REMOVAL


1. Remove the accelerator pedal assembly. Refer to PEDAL, ACCELERATOR, REMOVAL.
INSTALLATION
INSTALLATION



1. Install the accelerator pedal assembly. Refer to PEDAL, ACCELERATOR, INSTALLATION.

SENSOR, AIR TEMPERATURE, INTAKE
OPERATION
OPERATION
The IAT sensor provides an input voltage to the Powertrain Control Module (PCM) indicating the density of the
air entering the intake manifold based upon intake manifold temperature. At key-on, a 5-volt power circuit is
supplied to the sensor from the PCM. The sensor is grounded at the PCM through a low-noise, sensor-return
circuit.
The PCM uses this input to calculate the following:
Injector pulse-width
Adjustment of spark timing (to help prevent spark knock with high intake manifold air-charge
temperatures)
The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor.
REMOVAL
5.7L

Fig. 61: IAT Sensor - 5.7L

1 - FRONT OF INTAKE MANIFOLD PLENUM

2 - IAT ELECTRICAL CONNECTOR
The intake manifold air temperature (IAT) sensor (2) is installed into the front of the intake manifold air box
plenum.
1. Disconnect electrical connector (2) from IAT sensor.

2. Clean dirt from intake manifold at sensor base.

Fig. 62: IAT Sensor Tab/O-Ring

1 - IAT SENSOR
2 - SENSOR O-RING
3 - RELEASE TAB
Fig. 63: Identifying IAT Sensor - 5.7L



2 - IAT SENSOR
3 - RELEASE TAB
3. Gently lift on small plastic release tab (3) and rotate sensor about 1/4 turn counterclockwise for removal.
4. Check condition of sensor O-ring.
6.4L
Fig. 64: IAT Sensor & Electrical Connector - 6.4L

The intake manifold air temperature (IAT) sensor (1) is installed into the air intake hose.
1. Disconnect electrical connector (2) from IAT sensor.

2. Clean dirt from intake manifold at sensor base.

Fig. 65: IAT Sensor Tab/O-Ring

1 - IAT SENSOR
2 - SENSOR O-RING
3 - RELEASE TAB
3. Gently lift on small plastic release tab (3) and rotate sensor about 1/4 turn counterclockwise for removal.
INSTALLATION
5.7L

Fig. 66: Identifying IAT Sensor - 5.7L


2 - IAT SENSOR
3 - RELEASE TAB
plenum.

2. Clean sensor mounting hole in intake manifold.
3. Position sensor into intake manifold and rotate clockwise until past release tab.
4. Install electrical connector.
6.4L

Fig. 67: IAT Sensor & Electrical Connector - 6.4L

plenum.

2. Clean sensor mounting hole in intake manifold.
3. Position sensor into intake manifold and rotate clockwise until past release tab.
4. Install electrical connector.
SENSOR, CRANKSHAFT POSITION
DESCRIPTION
DESCRIPTION

Fig. 68: CKP Sensor - 5.7L

1 - CYLINDER BLOCK - RIGHT/REAR

2 - ELEC. CONNECTOR
3 - MOUNTING BOLT
4 - CKP SENSOR
The Crankshaft Position (CKP) (4) sensor is mounted into the right rear side of the cylinder block. It is
positioned and bolted into a machined hole.
OPERATION
OPERATION

Fig. 69: Crankshaft Position Sensor Operation & Notches

1 - RIGHT/REAR SIDE OF CYLINDER BLOCK

2 - MACHINED HOLE
3 - NOTCHES
Engine speed and crankshaft position are provided through the CKP (Crankshaft Position) sensor. The sensor
generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor
input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to
determine injector sequence and ignition timing.
The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain
distance from it.
A tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches (3) at its outer edge .
The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the
PCM.
REMOVAL
REMOVAL



2 - ELEC. CONNECTOR
3 - MOUNTING BOLT
4 - CKP SENSOR
The Crankshaft Position (CKP) sensor (4) is located at the right-rear side of the engine cylinder block. It is
positioned and bolted into a machined hole in the engine block.
1. Raise vehicle.
2. Disconnect CKP electrical connector at sensor.
3. Remove CKP mounting bolt (3).
4. Carefully twist sensor (4) from cylinder block.
5. Remove sensor from vehicle.
INSTALLATION
INSTALLATION



2 - ELEC. CONNECTOR
3 - MOUNTING BOLT
4 - CKP SENSOR
1. Clean out machined hole in engine block.

2. Apply a small amount of engine oil to sensor o-ring.
3. Install sensor (4) into engine block with a slight rocking and twisting action.
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.
4. Install mounting bolt (3) and tighten to 28 N.m (21 ft. lbs.) torque.
5. Connect electrical connector to sensor.
6. Lower vehicle.
SENSOR, MANIFOLD AIR PRESSURE (MAP)
OPERATION
OPERATION

The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based
sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion
chamber. The PCM requires this information to determine injector pulse width and spark advance. When
manifold absolute pressure (MAP) equals Barometric pressure, the pulse width will be at maximum.
A 5 volt. Reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold
pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0-15 psi, the voltage
changes 4.0V. To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the
low-noise, sensor return circuit at the PCM.
The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function
of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or
at a higher altitude, because the air density changes with altitude. It will also help to correct for varying
barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up,
barometric goes down. At key-on, the PCM powers up and looks at MAP voltage, and based upon the voltage it
sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the
voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-on.
The difference between current voltage and what it was at key-on, is manifold vacuum.
During key-on (engine not running) the sensor reads (updates) barometric pressure. A normal range can be
obtained by monitoring a known good sensor.
As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very
different altitude than where it was at key-on, the barometric pressure needs to be updated. Any time the PCM
sees Wide Open Throttle (WOT), based upon Throttle Position Sensor (TPS) angle and RPM, it will update
barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more
effectively.
The PCM uses the MAP sensor input to aid in calculating the following:
Manifold pressure
Barometric pressure
Engine load
Injector pulse-width
Spark-advance programs
Shift-point strategies (certain automatic transmissions only)
Idle speed
Decel fuel shutoff
The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm.
The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves
causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance
changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor
also contains electronics that condition the signal and provide temperature compensation.

The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading
stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes,
voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea
level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon
an object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in Hg. For every
100 feet of altitude, barometric pressure drops 0.10 in. Hg. If a storm goes through, it can change barometric
pressure from what should be present for that altitude. You should know what the average pressure and
corresponding barometric pressure is for your area.
REMOVAL
REMOVAL
Fig. 72: MAP Sensor & Electrical Connector

The Manifold Absolute Pressure (MAP) sensor (1) is located at the right rear of the intake manifold (2).
1. Disconnect the electrical connector (2) at the MAP sensor.

2. Rotate the MAP sensor 1/4 turn counterclockwise for removal.
3. Check the condition of the MAP sensor O-ring and replace if necessary.
INSTALLATION
INSTALLATION

Fig. 73: MAP Sensor & Electrical Connector

1. Clean the Manifold Absolute Pressure (MAP) sensor mounting hole at rear of intake manifold.
2. Check the condition of the MAP sensor O-ring seal and replace if necessary.
3. Position the MAP sensor (1) into intake manifold.
4. Rotate the MAP sensor 1/4 turn clockwise for installation.
5. Connect the electrical connector (2) to the MAP sensor (1).
SENSOR, OXYGEN
DESCRIPTION
DESCRIPTION
The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the
engine or emission package, the vehicle may use a total of either 2 or 4 sensors.
Federal Emission Packages : Two sensors are used: upstream (referred to as 1/1) and downstream (referred to
as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic
convertor. The downstream sensor (1/2) is located just after the main catalytic convertor.
California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as 1/1
and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor
(2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor
(1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream
sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main
catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-
catalytic convertor, and before the main catalytic convertor.
REMOVAL

5.7L
CAUTION: Never apply any type of grease to the oxygen sensor electrical connector,
or attempt any repair of the sensor wiring harness.
WARNING: The exhaust pipes and catalytic converter become very hot during engine
operation. Allow the engine to cool before removing the oxygen sensor.
Fig. 74: O2S Sensors


2. Disconnect the electrical connector from the O2 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.
3. Remove the O2 sensor with an oxygen sensor removal and installation tool.
4. Clean the threads in exhaust pipe using appropriate tap.
6.4L

CAUTION: Never apply any type of grease to the oxygen sensor electrical connector,
or attempt any repair of the sensor wiring harness.
WARNING: The exhaust pipes and catalytic converter become very hot during engine
operation. Allow the engine to cool before removing the oxygen sensor.
Fig. 75: Oxygen Sensors & Electrical Connectors

NOTE: Front O2 sensors shown in illustration. Rear sensors similar.

2. Disconnect the electrical connector from the O2 sensors (1, 2)
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. Remove the O2 sensor (4) with an oxygen sensor removal and installation tool.
4. Clean the threads in exhaust pipe using appropriate tap.
INSTALLATION
5.7L

Fig. 76: 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. Install the O2 sensor. Tighten to 41 N.m (30 ft. lbs.).

2. Connect the O2 sensor electrical connector.
3. Lower vehicle.
6.4L

Fig. 77: O2 Sensors & Electrical Connectors

NOTE: Rear O2 sensors shown in illustration. Fronts similar.
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. Install the O2 sensor (3, 5). Tighten to 50 N.m (37 ft. lbs.)
2. Connect the O2 sensor (1, 2) electrical connector.
3. Lower vehicle.
THROTTLE BODY
DESCRIPTION
DESCRIPTION
The throttle body is located on the intake manifold. Fuel does not enter the intake manifold through the throttle
body. Fuel is sprayed into the manifold by the fuel injectors.
REMOVAL
REMOVAL
CAUTION: Using a diagnostic scan tool, record any previous DTC's (Diagnostic
Trouble Codes).
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.

Fig. 78: Throttle Body - 5.7L

1. Disconnect and isolate negative battery cable from battery.

2. Remove air duct and air resonator box at throttle body.
3. Disconnect electrical connector (2) at throttle body.
4. Remove four throttle body mounting bolts (4).
5. Remove throttle body from intake manifold.

Fig. 79: Throttle Body O-Ring - 5.7L

1 - INTAKE MANIFOLD
2 - THROTTLE BODY O-RING
6. Check condition of throttle body O-ring (2).
INSTALLATION
INSTALLATION

Fig. 80: Throttle Body O-Ring - 5.7L

1 - INTAKE MANIFOLD
2 - THROTTLE BODY O-RING
1. Clean and check condition of throttle body-to-intake manifold O-ring (2).

2. Clean mating surfaces of throttle body and intake manifold.
3. Install O-ring (2) between throttle body and intake manifold.
4. Install throttle body to intake manifold by positioning throttle body to manifold alignment pins.
5. Install all throttle body mounting bolts finger tight.

Fig. 81: Throttle Body Tightening Sequence

CAUTION: The throttle body mounting bolts MUST be tightened to

specifications. Over tightening can cause damage to the throttle
body or the intake manifold.
6. Obtain a torque wrench. Tighten mounting bolts (as shown in illustration) in a mandatory torque criss-
cross pattern sequence to 5.6 N.m (50 in. lbs.).
Fig. 82: Throttle Body - 5.7L

7. Install electrical connector (2).

8. Install air plenum to flange (3).
9. Connect negative battery cable.
10. Using the diagnostic scan tool, erase all previous DTC's and perform the ETC Relearn function.
VALVE, SHORT RUNNER
DESCRIPTION
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.
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
5.7L
Fig. 83: Battery

1. Disconnect the negative battery cable (1).

Fig. 84: Intake Manifold Retaining Bolt Removal & Tightening Sequence
2. Remove the intake manifold and throttle body as an assembly. Refer to MANIFOLD, INTAKE, GAS,
REMOVAL, 5.7L .
Fig. 85: Short Runner Valve Actuator Retaining Bolts

3. Remove the short runner valve actuator retaining bolts (1) and remove valve.

Fig. 86: Short Runner Valve Actuator Rubber O-Ring Seal

4. Remove and discard the short runner valve actuator rubber O-ring seal (1).
6.4L
Fig. 87: Battery

1. Disconnect the negative battery cable (1).

Fig. 88: Short Runner Valve Components

2. Remove the Short Runner Valve (SRV) cover (1).

3. Remove the short runner valve actuator retaining bolts (3) and remove valve.

4. Remove and discard the short runner valve actuator rubber O-ring seal (1).
INSTALLATION
5.7L


1. Install a new short runner valve actuator rubber O-ring seal (1).
Fig. 91: Short Runner Valve Actuator Retaining Bolts

2. Position the short runner valve actuator, install the retaining bolts (1) and tighten to 5 N.m (44 in. lb.).

Fig. 92: Intake Manifold Retaining Bolt Removal & Tightening Sequence
3. Install the intake manifold and throttle body as an assembly. Refer to MANIFOLD, INTAKE, GAS,
INSTALLATION, 5.7L
Fig. 93: Battery

6.4L


1. Install a new short runner valve actuator rubber O-ring seal (1).
Fig. 95: Short Runner Valve Components

2. Position the short runner valve (SRV) actuator (2) to the intake manifold. Tighten the retaining bolts (3)
to 5 N.m (44 in. lb.).
3. Install the SRV cover (1).

Fig. 96: Battery

FUEL DELIVERY, CNG

WARNING
WARNING
ANY service that is required on the Compressed Natural Gas, purging of the fuel tube system must be
done . Refer to FUEL TUBE PURGING - CNG .
If a physical inspection of the CNG cylinder tanks is required. Refer to CYLINDER, FUEL, INSPECTION.
Any service required on the CNG cylinder tanks must be done by a certified CNG service technician .
WARNING: Before performing any service or repair on Compressed Natural Gas

(CNG) equipped vehicles, the following warnings and safety precautions
must be read and followed:
The CNG system should be serviced only by qualified natural gas

vehicle technicians
Natural gas vapors at atmospheric pressure are lighter than air and
will rise and disperse in open areas. In enclosed areas, natural gas
vapor may collect and form a combustible mixture. If the vehicle is
routinely placed in an enclosed area, the area should be provided
with adequate ventilation and/or a natural gas detection system. For
long term storage, the manual shutoff valve and each individual fuel
control valve should be closed.

A fire or explosion could result if a source of ignition or flame is

present with natural gas in a confined-unventilated area. Provide
proper ventilation when servicing CNG vehicles.
Natural gas contains an odor additive. Occasionally, mild natural gas
odors may be noticed during engine starting and after engine shut
down. This is because of small quantities of unburned gas in the
engine intake and exhaust manifolds. While these are normal, as are
gasoline odors in similar circumstances, a persistent odor of natural
gas indicates a leak is present. Have the vehicle checked
immediately for source of leak. If a leak is determined to exist, do not
bring the vehicle into an unventilated area.
Do not attempt to weld any part of the fuel cylinders or any other fuel
system component.
Do not attempt to modify any fuel system component or replace any
component with parts that do not meet Chrysler corporation
requirements.
Do not apply any paint or undercoating material to any fuel system
component.
Do not attempt to force open or tamper with any fuel tubes or valves.
A sudden release of high-pressure gas may occur resulting in bodily
injury.
Do not park or service vehicle near any source of excessive heat or
open flames.
Do not use a paint oven to cure any paint repairs as CNG fuel
cylinders on these vehicles are equipped with pressure relief safety
devices. These devices will vent to the atmosphere at approximately
103°C (217°F).
When a vehicle has been involved in an accident which may have
caused damage or dislocation to the CNG system, the system
should be inspected and pressure tested. This should be done
before being returned to service.
Any fuel system component, including the cylinders, that have been
subjected to fire, may not be returned to service due to reduced
pressure capability.
U.S. Requirements: Each CNG fuel cylinder manufactured on or after
March 27, 1995 must be removed and reinspected after a motor
vehicle accident or fire and at least every 36 months or 36, 000 miles
(whichever comes first) for damage and deterioration in accordance
with Motor Vehicle Safety Standard No. 304 Compressed Natural Gas
Fuel Containers And Compressed Gas Association (CGA), Arlington,
VA. Guidelines C-6.4. Retest markings must be stamped on the
cylinder neck or marked on a label securely affixed to the cylinder
and overcoated with epoxy near the original test date. Reheat
treatment or repair of rejected cylinders is not authorized. The fuel

cylinder expires and must be removed from service fifteen years

from the date of manufacture. A label on the fuel filler door states
the cylinder expiration date. A similar label is attached to each fuel
cylinder. If there is a question about the proper inspection of the
CNG cylinder, contact the manufacturer as identified on the cylinder
label.
Canadian Requirements: The cylinder must be reinspected after a
motor vehicle accident or fire and at least every 36 months or 36, 000
miles (whichever comes first) for damage and deterioration in
accordance with Canadian Standards Association (CSA) B51-97,
Part 2 High-Pressure Cylinders For The Onboard Storage Of Natural
Gas As A Fuel For Automotive Vehicles And Compressed Gas
Association (CGA), Arlington, VA. Guidelines C-6.4. Retest dates
must be stamped on the exposed metallic surface of the cylinder
neck or marked on a label securely affixed to the cylinder and
overcoated with epoxy near the original test date. Reheat treatment
or repair of rejected cylinders is not authorized. The fuel cylinder
expires and must be removed from service fifteen years from the
date of manufacture. A label on the fuel filler door states the first
cylinder expiration date. It is recommended that the fuel system
components be inspected periodically for leaks and/or excessive
wear.
Fuel the vehicle using a NGV 1 certified fill nozzle as specified on the
label inside the fuel filler door. Do not attempt to fuel the vehicle with
any other type of nozzle
Before any part of the CNG fuel system is opened for repair, the
system must be purged of all natural gas. Refer to FUEL TUBE
PURGING - CNG.
WARNING: THE MANUAL SHUT-OFF VALVES ARE NON SERVICEABLE. DO NOT

REMOVE THE MANUAL SHUT-OFF VALVE FROM THE CNG CYLINDER
TANKS. REMOVAL OF THE VALVE MAY CAUSE ONE OR MORE OF THE
FOLLOWING: THE COMPRESSED GAS IN THE CYLINDER TANK MAY
RUSH OUT RAPIDLY ENOUGH TO CAUSE THE VALVE AND/OR THE
CYLINDER TANK TO BECOME A PROJECTILE: MAY CAUSE A FLAME AT
THE TANK AND/OR A FIRE TO OTHER NEAR BY COMBUSTIBLES; MAY
CAUSE AN EXPLOSION OF THE CNG CYLINDER TANK; MAY DISPLACE
OR DEPLETE AIR IN A CONFINED WORK SPACE; OR MAY CAUSE
LEAKED CNG TO COLLECT IN CEILING LIKE AREAS IN SUFFICIENT
QUANTITIES AND MIXTURE TO BECOME COMBUSTIBLE OR EXPLOSIVE.
WARNING: NEVER STORE A CNG VEHICLE OR CYLINDER TANK UNATTENDED IN A

FACILITY NOT SPECIFICALLY DESIGNED FOR THE STORAGE OF
NATURAL GAS.

WARNING: The first high pressure component to be serviced, must be loosened

slowly, so that the pressure inside the fuel system can adjust to ambient
pressure.
WARNING: Extreme care must be taken when servicing the CNG tank. Any type of
minor damage to the CNG tank (for example, a.025 in nick, scratch or
dent) can render the CNG tank unusable. Any damage, regardless of how
minor, requires the tank to be officially inspected and re-certified. Before
working around the CNG tank perform a visual inspection to ensure no
damage is present, if any damage is discovered, do not service this
vehicle until a certified Inspector can certify that the CNG tank is safe.
SPECIFICATIONS
SPECIFICATIONS - CNG
Liquid Gas Fuel Pressure at Fuel Rail 58 psi +/- 2 psi

Compressed Natural Gas Fuel Pressure to Regulator 230 - 4, 200 psi +/- Temperature at the Tanks
Compressed Natural Gas Fuel Pressure Internal
230 psi
Regulator
Compressed Natural Gas Fuel Pressure after
163 psi
Regulator
Compressed Natural Gas Fuel Pressure Relief
4, 800 - 5000 psi
Device
TORQUE

Accelerator Pedal Bracket 12 - 105
Mounting
Accelerator Pedal Position 3 - 30
Sensor Bracket-to-Battery Tray
Bolts
Camshaft Position Sensor - 5.7L 12 9 105 (+/-) 20
Crankshaft Position Sensor - 5.7L 12 - 105 (+/-20)
EVAP Canister- to-Bracket Nuts 8.5 - 75
EVAP Canister-to-Frame Bolts 34 25 -
Ignition Coil Mounting Bolts 11 - 100
Oxygen Sensors 41 30 -
PCM-to-Mounting Bracket
4 - 35
Mounting Screws
Throttle Body Mounting Bolts - 5.6 - 50
5.7L

LIQUID FUEL SIDE

Fuel Filler Housing-to-Body
2 - 17
Screws
Fuel Rail Mounting Bolts - 5.7L 5 - 44
Fuel Tank Mounting Straps 41 30 -
Fuel Tank Mounting Bolts - 52
55 41 -
Gallon Tank
CNG FUEL SIDE

Access Door to 1/4 Turn Valve 6 - 53
1/4 Turn Valve Screws 5 - 44
CNG Fuel Line Pressure Fittings 35 26 -
CNG Fuel Rail Mounting Bolts -
5 - 44
5.7L
Cylinder Tank Cage Bolts 21 16 -
Cylinder Tank Cage Base Bolt 20 15 -
Cylinder Tank Cover Bolts 53 39 -
Cylinder Tank Support Strap
53 39 -
Bolts
CNG Pressure Regulator to
21 16 -
Bracket Bolts
CNG Shut-Off Relay Nut 7 - 62
CNG Pressure Regulator Bracket
9 - 80
to Bulkhead
DESCRIPTION
DESCRIPTION-CNG
WARNING: Refer to FUEL DELIVERY, CNG, WARNING.

Fig. 97: CNG Fuel System

The Compressed Natural Gas (CNG) fuel system is equipped with the 5.7 liter engine.
The CNG vehicle still utilizes gasoline. The engine operates using gasoline when the temperature is below 18°C
(64.4°F) before switching to CNG. The engine will switch back to gasoline when the CNG system falls below
the low fuel threshold.
CNG is in the cylinder tanks (4) and is always under high pressure even when the vehicle is at rest. With the
CNG fuel system under extreme pressure, the use of a fuel pump is not required in the CNG system.
The Ram 2500 CNG engine starts and runs on CNG for all starts, when the engine coolant temperature is at or
above 18°C (64.4°F). To make sure the gasoline does not get stale, the PCM uses a "Minimum Gasoline
Consumption" feature. This feature will consume one tank of gasoline about every 8000 miles regardless of
tank size. The routine will force the engine to run on gasoline until a programmed amount of gasoline is used.
The routine will never run more than once per ignition cycle.
When the engine coolant temperature is between approximately -18°C (0.0°F) and +18°C (64.4°F), the Ram
2500 CNG will start and run on gasoline until these conditions are meet:
The engine coolant temperature is above +10°C (50°F)

The vehicle speed is above 24 KPH (15 MPH)
The driver coasts (releases the accelerator pedal with the transmission in gear)
If a gas consumption event is required during a cold-start ignition switch cycle, the amount of gasoline
consumed during operation of the Minimum Gasoline Consumption routine will be reduced by the amount of

gasoline consumed during the cold start.
When a start occurs with the ambient temperature below approximately -18C (0.0°F), the gasoline consumed
after the cold start will exceed the amount required by the Minimum Gasoline Consumption feature. The routine
will not run during that key cycle.
However, certain high-load conditions may cause the fuel system to switch from CNG back to gasoline. For
example, the system will switch to gasoline operation whenever the driver keeps the engine at wide open
throttle for an extended period of time.
Because of the high pressure. A pressure regulator (2) is used to control the CNG entering the fuel rail to a
lower consistent pressure.
Additional or unique components used with CNG fuel system include:
A shut-down relay
An NVG-1 high-pressure fuel fill receptacle with an internal one-way check valve and 50 micron
Two high-pressure fuel cylinders (4)
Manual fuel control valves (on each fuel cylinder)
CNG high-pressure fuel shut-off solenoids
A separate, one-way check valve near the 1/4 turn gas shut-off valve on the filler line
A manual (mechanically operated) 1/4 turn gas shut-off valve
A canister style filter (5) located in the cylinder tank cabinet
High-pressure, stainless steel seamless fuel lines (3)
Single-ferrule, compression-type fuel tube (line) fittings
A 50 micron fuel filter mounted in the fuel pressure regulator inlet
High pressure sensor mounted on the inlet side of the pressure regulator.
A fuel pressure regulator warmed by engine coolant (2)
A compression-type flexible steel line (1)
A fuel rail mounted, fuel low-pressure/ temperature sensor
A unique fuel rail
Eight unique CNG fuel injectors
Two relay packs to control the switching of the injectors between gasoline and CNG.
A fuel pressure regulator mounted, and electrically controlled, high-pressure fuel shut-off solenoid
A unique Powertrain Control Module (PCM) computer
Certain unique wiring harnesses
DESCRIPTION
The electric fuel pump is located inside of the fuel pump module. A 12 volt, permanent magnet, electric motor
powers the fuel pump. The electric fuel pump is not a separate, serviceable component.

For fuel pump module removal. Refer to MODULE, FUEL PUMP, REMOVAL .
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - HARD TO FILL WITH FUEL
1. Disconnect the vapor recirculation tube at the fuel tank.

2. Attempt to refill fuel tank.
3. Does tank refill properly?
a. Yes >> Proceed to next step.
b. No > Proceed to step 8.
4. Reconnect the vapor recirculation tube at the fuel tank.
5. Disconnect the other end of the vapor recirculation tube at the fuel filler tube.
a. Yes >> Replace fuel filler tube.
b. No > Replace the vapor recirculation tube.
8. Disconnect the control valve to vapor canister tube at the fuel tank.
9. Reconnect the vapor recirculation tube at the fuel tank.
a. Yes >> Replace fuel tank.
b. No > Proceed to step 11.
11. Reconnect the control valve to vapor canister tube at the fuel tank.
12. Disconnect the control valve to vapor canister tube at the EVAP canister.
a. Yes >> Blockage is in the vapor Canister, or Evaporative System Integrity Monitor (ESIM), or
Clean air hose (ESIM vent hose), or filter. Diagnose appropriately.
b. No > Replace the control valve to vapor canister tube.
DIAGNOSIS AND TESTING - TESTING FOR FUEL LEAK - CNG
For Compressed Natural Gas (CNG) powered vehicles:

Fig. 98: Air Leak Detection Fluid

If a leak is suspected at a fuel tube, a fuel tube fitting or fuel system component, obtain a commercially
available air leak detection fluid. When inspecting for leaks, be sure fuel is under operating pressure. Apply a
generous amount of leak detector fluid to the suspected leak area. Watch the area for approximately 3 to 5
minutes. In most cases, if there is a leak, a steady flow of bubbles will appear from the leak source. Refer to the
appropriate Service Information for repair procedures.
NOTE: The use of a soap and water mixture may cause a corrosive reaction to the CNG
fuel system and is not recommended.
STANDARD PROCEDURE
FUEL TUBE PURGING - CNG
NOTE: If required, perform the gasoline system fuel pressure release . Refer to FUEL
SYSTEM PRESSURE RELEASE.
NOTE: BEFORE ANY PART OF THE COMPRESSED NATURAL GAS (CNG) FUEL
SYSTEM IS OPENED FOR REPAIR, THE SYSTEM MUST BE PURGED OF ALL
NATURAL GAS. PURGING OF THE SYSTEM IS RECOMMENDED OUTDOORS
OR A WELL VENTILATED AREA.

NOTE: When purging the system. Not all of the CNG will be evacuated. Care must be
taken when purging the CNG system.
Use following procedure if the fuel injector rail is not equipped with a fuel pressure test port.
Fig. 99: CNG 1/4 Turn Valve Access Panel

1. Open the CNG 1/4 turn valve access panel (2).

Fig. 100: 1/4 Turn Valve Positions

2. Verify the 1/4 turn valve is in the
OPEN
position.
3. Close the CNG cylinder tank manual shut off valves.
NOTE: When both the gasoline and CNG fuel systems are operating normally and
the engine coolant temperature above 18°C, the engine should start in
CNG mode. If the engine is not operating in CNG mode, use wiTECH® to
force CNG mode.
NOTE: If the vehicle is unable to start. Cycle the ignition key multiple times to
verify the CNG cylinder tanks are closed.
4. Start and run engine.

5. Monitor the pressure drop by the CNG fuel level indicator.
NOTE: After the engine switches to gasoline mode, verify lower system pressure
by monitoring the fuel gauge in the instrument cluster or the CNG tank
pressure sensor using wiTECH®.

6. Verify that the engine is operating on gasoline.

7. Monitor the cylinder tank high pressure sensor and the fuel rail sensor by using the wiTech®.
8. Turn ignition key to OFF position.
NOTE: The
LOW SIDE
line needs to be slowly open in order to verify the system does not have a
faulty shut-off valve or regulator.
9. Using care. Loosen the low pressure line at the fuel rail.
10. Using care. Loosen the high pressure supply line to the fuel pressure regulator.
NOTE: ALTHOUGH THE FUEL TUBES ARE NOW PURGED OF CNG, THE FUEL
CYLINDERS ARE STILL UNDER HIGH-PRESSURE. DO NOT OPEN THE
VALVES UNTIL ALL HIGH-PRESSURE COMPONENTS HAVE BEEN
RESEALED.
The fuel system must first be purged of natural gas if any of the following components are to be removed
or repaired:
Any fuel tube (line) or fuel tube fitting

The fuel injector rail assembly
Any or all fuel injectors
The fuel temperature sensor
The fuel low-pressure sensor
The fuel gauge pressure sensor
The fuel fill receptacle
Any fuel cylinder
Any fuel control valve
The 1/4 turn manual shut-off valve
The fuel filters
The one-way check valves
Pressure regulator
The low-pressure fuel shut-off solenoid
The high-pressure solenoid
NOTE: One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM
memory due to a possible rough idle condition. A diagnostic scan tool must be
used to erase a DTC.

FUEL SYSTEM PRESSURE RELEASE
A separate fuel pump relay is no longer used. A circuit within the Power Distribution Center (PDC) is
used to control the electric fuel pump located within the fuel pump module.
1. Remove the fuel fill cap.

2. Remove the cover (1) from the housing base (2).
3. Remove fuse from the PDC.
4. Start and run the engine until it stalls.
5. Attempt restarting the engine until it will no longer start.
6. Turn the ignition key to the OFF position.
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.
NOTE: Excessive fuel spillage onto the gaskets can cause gaskets to expand and
dislodge from gasket groove.
7. Place a rag or towel below the fuel line quick-connect fitting at the fuel rail.
8. Disconnect the fuel line quick-connect fitting at the fuel rail (1) and plug with a shipping cap to prevent
spillage. Refer to FITTING, QUICK CONNECT - STANDARD PROCEDURE .
NOTE: One or more Diagnostic Trouble Codes (DTC's) may have been stored in the
PCM memory due to disconnecting fuel pump module circuit. A diagnostic scan
tool must be used to erase a DTC.

DRAINING FUEL TANK
WARNING: The fuel system may be under constant fuel pressure even with the
engine off. This pressure must be released before servicing the fuel tank.
Due to a one-way check valve installed into the fuel fill fitting at the tank, the tank cannot be drained at the fuel
fill cap.
2. Disconnect the fuel supply line (2) from the fuel rail. Refer to FITTING, QUICK CONNECT -

Fig. 103: Fuel Line Adapters

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 Decay Tool, Fuel 8978A to the fuel supply line.
Route the opposite end of this hose to an OSHA approved fuel storage tank such as the John Dow Gas
Caddy 320-FC-P30-A or equivalent.
4. Using a diagnostic scan tool, activate the fuel pump until the fuel tank has been evacuated.
Fig. 104: Battery


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. Perform the Fuel System Pressure Release procedure. Refer to FUEL SYSTEM PRESSURE
RELEASE .
3. Raise and support the vehicle.
Fig. 105: Fuel Pump Module

5. Remove the fuel pump module (1). Refer to MODULE, FUEL PUMP, REMOVAL .
6. Position a 3/8" hose into the fuel pump module opening of the fuel tank.
7. Attach the opposite end of this hose to the Fuel Chief Gas Caddy 320-FC-P30-A or an OSHA approved
gas caddy.
8. Using the gas caddy, evacuate the fuel tank.
CYLINDER, FUEL
DESCRIPTION
DESCRIPTION
Two high-pressure fuel tanks located under a steel cabinet located in the bed of the vehicle. Each tank has its
own manual shut off valve assembly with a built in safety valve that's electronically controlled.
OPERATION
OPERATION


NATURAL GAS.
The 2 cylinders store natural gas at pressures up to approximately 3600 psi.
Each fuel cylinder is equipped with its own manually operated fuel control valve. Each of these valves is
equipped with a pressure relief safety device.
A states the fuel cylinder (container) expiration date. A similar label is attached to each individual fuel cylinder.
The label on the fuel cylinder will state: the address of the fuel cylinder manufacturer; the cylinder expiration
date; certain warnings; and cylinder certification numbers.
INSPECTION
INSPECTION
CAUTION: Before removing cylinders from cylinder carrier, note and mark cylinder
position in relation to cylinder carrier. Also note horizontal/vertical
positions of each fuel control valve. This must be done in order to install
each cylinder fuel control valve back to its original horizontal position.
CAUTION: It is highly recommended when moving or transporting the CNG cylinder

tanks that they are covered with a blanket to avoid scratching or damaging
the tanks.

NATURAL GAS.
The inspection of the containers must be done according to the procedures provided in CGA C-6.4 -2007.
The inspection shall be carried out by a qualified container inspector recognized by the Authority having
jurisdiction, as defined in Section 5 of CGA C-6.4 and with the equipment defined in Section 6 of CGA
C-6.4.

The container external surface must be clean for an effective inspection (see Section 7 of CGA C-6.4 -
2007). If this is not the case, the container must be cleaned with a water - based detergent. The use of
abrasives and/or solvents should be avoided. If protective cover materials (stone shields and other
protective covers) prevent an effective inspection, they must be removed prior to inspection.
Each container shall be visually inspected for external damage and deterioration on the whole external
surface, including under the support straps.
To properly examine the external surface of the container a light source capable of illuminating all
surfaces should be used. The decision about the necessity to un-install the containers for inspection is up
to the qualified inspector and under his complete responsibility on the basis of visual damage or unless
deteriorations noted on the exposed container.
Each container shall be visually inspected at least every 36 months or every 36.000 miles whichever
comes first. Special inspection shall be performed if exists the conditions defined in Section 7 of CGA C-
6.4 -2007 (Accidents and overheat, Chemical damages and over pressurization, Unusual behavior, Re-
installation).
Visual examination of the surface is made to detect container damage or evidence of potential damage
like corrosion, cuts, scratches, gouges, fractures, material loss/removal, discoloration of the container
surface (soot, charring, chemical attack, etc.), evidence of impact or accidents, and deterioration of the
surface.
Decision
Damage Definition
Accept Reject
Mandatory information
(see 14.1.1 of ANSI
Marking and Stamped and attached Required information are
NGV2-2007) are not
Labelling information present and legible
legible.
See also 2.8.
A sharp impression
where material has been
Cuts removed or redistributed, When depth of damage is
When depth of damage is
Scratches including line corrosion less than or equal to 0.25
greater than 0.25 mm
Gouges where pits are connected mm
or closer than one pit
width from each other
An area that is scuffed or
worn When depth of damage is
Abrasion less
thinner by rubbing or greater than 0.25 mm
than or equal to 0.25 mm
scraping
Loss of content through
Gas leakage None detected Any type of leakage
a defect
Visible swelling of
Bulge None Any visible or detectable
container
Permanent discoloration,
Chemical attack Container is subjected to Cleans off, no residue and loss/disruption of material,
chemical that the chemical is known not chemical is known to
dissolves or destroys the to affect container affect container materials;

material materials can't determine if materials

have been affected
A hole caused by a When depth of the pit is
When depth is greater than
Corrosion, pits chemical, oxidation or less than or equal to 0.25
0.25 mm
rusting of material mm
A series of corrosion pits
connected in a narrow
band such that the When the depth of damage
Corrosion, line less than or equal to 0.25
distance between pits is is greater than 0.25mm
mm
greater than one pit
width.
Dents 1.6 mm or more
A depression in the
deep, or the largest
container that has Dents less than 1.6 mm
diameter/length is less than
Dents neither penetrated nor deep and larger than 50
50 mm (regardless of dent
removed mm in diameter/length
depth), or both conditions
material
exist
Containers that have been involved in accident, which may have damaged the container, or containers
with known or suspected damage shall be depressurized prior to examination (see 7.3.3 C of CGA C-6.4 -
2007).
The only allowable repair is the paint repair (touch up) that shall be done after the necessary preparation.
The touch up must be done with 2 layers of paint for a minimum total thickness of 70m using a first layer,
zinc rich primer. The second layer, polyurethane or epoxy paint.
Containers without labels containing mandatory information, or with labels containing mandatory
information which is illegible in any way, shall be removed from service. If the container can be
positively identified by manufacturer and serial number, a replacement label supplied by the manufacturer
may be applied to the container, and it may remain in service.
Containers having damages accepted or repaired must be monitored at every periodic inspection in order
to detect if the dimensions are increasing. Should defect dimensions increase the container shall be
scrapped.
This document cannot be used as a guideline for maintenance or repair of the containers by anyone who is
not a qualified inspector appointed by the Authority having jurisdiction.
It must be assumed that abnormal or unusual circumstances suggest further requirements or additional
procedures.
REMOVAL
REMOVAL
WARNING: Refer to FUEL DELIVERY, CNG, WARNING

Fig. 106: Battery

NOTE: The CNG system may be under high pressure at all times. Before servicing the
CNG system. The fuel line purging procedure must be performed.
1. Perform the fuel CNG fuel tube purging. Refer to FUEL TUBE PURGING - CNG .
Fig. 107: Cylinder Tank Cover Support Brackets & Retainers


3. Remove the cylinder tank cover support brackets (1).
Fig. 108: Upper And Rear Cylinder Tank Covers & Fasteners
4. Remove the upper (2) and rear (4) cylinder tank covers.
NOTE: Before any cylinder tank procedures are performed. An Inspection of the
tanks must be done.
Refer to CYLINDER, FUEL, INSPECTION.

Fig. 109: Quarter Turn Valve Mount Bracket & Fasteners

5. Remove the quarter turn valve mount screws (3).

6. Remove the two inner bolts (1) that secure the quarter turn valve bracket (2) to the cylinder tank valve
cage.

Fig. 110: Cylinder Valve Cages & Fasteners

7. If required, remove the cylinder valve cage (4, 5).
Fig. 111: Cylinder Tank Valve, Connectors & Lines

8. Disconnect the cylinder tank valve solenoid electrical connector.

9. If required, remove the supply line to the front cylinder tank valve (1).
10. Remove the cylinder connecting line (7) from the tanks.
11. Reinstall the cage onto the cylinder tank.

Fig. 112: Cylinder Tank, Straps & Bolts

12. Remove the cylinder tank support strap bolts (1).
CAUTION: It is highly recommended when moving or transporting the CNG

cylinder tanks that they are covered with a blanket to avoid
scratching or damaging the tanks.

Fig. 113: Cylinder Tank, Support & Straps

13. Remove the straps (1) from the cylinder tank support (3).
Fig. 114: Cylinder Tanks & CNG Lifting Sling


14. With the use of an assistant. Lift the cylinder tanks (1) enough to install (special tool #10380, Sling,
CNG, Lifting).
Fig. 115: Cylinder Lifter Tools

(2).

Fig. 116: Lifting Cylinder

15. Using an engine lift or compatible, lift the cylinder tanks enough to allow the tanks to clear the bed.
16. Set the cylinder tanks in a well ventilated location.
NOTE: Removal of the cylinder tank valve cages is not recommended unless
necessary for replacement.

Fig. 117: Cylinder Cage & Support Base

17. If required, remove the cylinder tank cage.

18. Remove the cage support base (1).
INSTALLATION
INSTALLATION

Fig. 118: Cylinder Cage & Support Base

1. If removed, install the cylinder tank cage base (1) around the manual shut off valve (2). Tighten the bolt
(3) to 20 N.m (15 ft. lbs.).
2. Install the cylinder tank manual shut off cage. Hand tighten the bolts.
CAUTION: It is highly recommended when moving or transporting the CNG

cylinder tanks that they are covered with a blanket to avoid
scratching or damaging the tanks.

Fig. 119: Lifting Cylinder

3. Secure the fuel tank onto a suitable hydraulic jack with (special tool #10380, Sling, CNG, Lifting)
4. Raise and position the fuel tank leaving room to clear the vehicle bed.
Fig. 120: Cylinder Tank, Straps & Bolts

5. Align the cylinder tank (3) to the tank support (4).

6. Remove the (special tool #10380, Sling, CNG, Lifting).
7. Loosely install the lines to the cylinder tank.
Fig. 121: Cylinder Tank, Support & Straps

8. Install the cylinder tank strap (1).

9. Tighten the strap bolts to 53 N.m (39 ft. lbs.).


10. Connect the electrical connector (5) to the cylinder tank shut down solenoid.
11. Tighten the cylinder pressure fittings (6, 8) to 35 N.m (26 ft. lbs.).
12. If removed, install the supply line from the 1/4 turn valve (2). Tighten fitting to 35 N.m (26 ft. lbs.).
13. Open the cylinder tank manual valves and the 1/4 turn valve.
14. Fill the CNG system.
15. Check for leaks using an air leak detection fluid on all the fittings.

Fig. 123: Cylinder Valve Cages & Fasteners

16. If removed, position the cylinder tank cage (4, 5) onto the cage base (2). Loosely install the outer bolts (1,
3).


17. Install the 1/4 turn valve mounting bracket (2) to the cages. Tighten the bolts to 21 N.m (16 ft. lbs.).
18. Tighten the 1/4 turn valve to bracket screws (3) to 5 N.m (44 in. lbs.).
19. Install the cylinder tank covers (2, 4).

20. Tighten the bolts (1, 5 and 6) to 53 N.m (39 ft. lbs.).

Fig. 126: Cylinder Tank Cover Support Brackets & Retainers

21. Install the cylinder tank cover support bracket. Tighten the bolts (2) to 53 N.m (39 ft. lbs.).
Fig. 127: Battery


23. Start the engine and check for leaks using an air leak detection fluid at all fuel tank connections.

FILTER, FUEL
DESCRIPTION
CNG IN-LINE
The gasoline fuel filters consist of two filters that are located at the bottom of the fuel pump module and inside
the module. A separate frame mounted fuel filter is not used with any engine. If the fuel filters for the gasoline
fuel pump require service. Refer to MODULE, FUEL PUMP, REMOVAL .
The CNG fuel system consist of three re-placable in-line filters to aid in moisture and debris removal.
Fig. 128: Exploded View Of Filler Nozzle

The filler nozzle located under the gas service cap consist of a 50 micron filter (3). This filter is re-placable. If
the filter requires service, refer to REGULATOR, FUEL PRESSURE .

Fig. 129: Micron Filter & Pressure Regulator

The re-placable high pressure 50 micron filter (1) is located at the inlet side of the pressure regulator. The
pressure regulator is located on the bulk head on the right side of the engine.
CNG CARTRIDGE
Fig. 130: Exploded View Of CNG Cartridge


A 5 micron woven fiber cartridge (2) located in a pencil style cylinder. The filter assembly is located in the
cylinder tank cabinet.
Fig. 131: In-Line Adapter Fitting & Crush Washer

The in-line adapter fitting is used to connect the CNG lines to the upper canister housing. An aluminum crush
washer seals the fitting to the housing. If loosened or removed. The washer and fitting must be replaced.
OPERATION
OPERATION


The cartridge style filter utilizes a replaceable cartridge filter (2). The filter allows the compressed natural gas to
be filtered down to 5 microns. Moisture in the system will settle in the lower bowl (4).
The upper housing (1) is marked so that the high pressure lines are install in there proper order of flow. The
upper housing mounts to a bracket rearward of the cylinder tank support assembly.

Fig. 133: Upper CNG Cartridge Housing

Fig. 134: Upper Housing, Washer & Adapter Fitting

The upper housing (1) utilizes an adapter fitting (3). An aluminum washer (2) is used to seal the fitting to the
upper housing.
REMOVAL

REMOVAL
1. Perform the CNG fuel tube purge. Refer to FUEL TUBE PURGING - CNG .
2. Remove the upper cylinder tank cabinet cover (2).
NOTE: If replacing the cartridge filter in vehicle. It is recommended that the upper
filter housing be held in place to reduce the stress to the mounting bracket
and the fuel lines when the lower housing is being loosened.


3. If replacing the cartridge filter (2). Remove the lower housing bowl (4).
4. Remove the filter by pulling down and away from the upper housing (1).
Fig. 137: Fuel Lines & Filter Housing Mounting Bolts


5. If removing the filter housing, remove the supply line (1).
NOTE: The adapter fitting (4) can only be used one time. If loosened or removed.
It must be replaced.
6. Remove the feed line (5) from the adapter fitting (4).
7. If required, remove the adapter fitting and discard.
8. Remove the filter housing mounting bolts (2).
INSTALLATION
INSTALLATION
NOTE: If replacing the cartridge filter in vehicle. It is recommended that the upper filter
housing be held in place to reduce the stress to the mounting bracket and fuel
lines when the lower housing is being tightened.

1. Lubricate the O-ring (3).

2. Install a new cartridge style filter (2) into the upper filter housing (1).
3. Press the filter into the mount firmly to allow the upper filter to seal properly against the upper housing.
4. Install the lower bowl (4). Tighten to 40 N.m (30 ft lbs).

Fig. 139: Fuel Lines & Filter Housing Mounting Bolts

5. If replacing the filter housing assembly (5). Position the housing to the mounting bracket. Tighten the
bolts (2) to 21 N.m (16 ft lbs).
6. If removed, install a new adapter fitting (4). Tighten the fitting to 75 N.m (55 ft lbs).
7. Install the feed line (5). Tighten the line to 35 N.m (26 ft lbs).
8. Install the supply line (1). Tighten the line to 35 N.m (26 ft lbs).
9. Fill the CNG system.
10. Check for leaks using a air leak detection fluid.

11. Install the cylinder tank cabinet upper cover (2). Tighten the bolts (1) to 53 N.m (39 ft lbs).
LINES, FUEL
DESCRIPTION
DESCRIPTION
BEFORE REMOVAL: Due to the special service requirements required for these tubes, lines or fittings,
also see WARNINGS and SAFETY PRECAUTIONS.
Due to the high-pressure requirements of the CNG system, special stainless steel, SAE straight thread, single-
ferrule, compression-type fuel tube fittings are used. These will connect all fuel tubes and components on the
high-pressure side of the system (inlet side of the fuel pressure regulator).
WARNING: Due to the extreme high pressures of the CNG fuel system, certain
precautions must be taken when handling or servicing fuel tubes or fuel
tube fittings:
Where applicable, use only single-ferrule compression type fittings

on the CNG system. If a fitting must be replaced, use only an original
equipment replacement part.
When handling fuel tubes, do not allow ends of tubes to get
scratched. Small scratches are a potential source of a leak.

Always check and remove any burrs from the end of tubes before
installing fittings.
After some types of high-pressure fittings are tightened, a go no-go
gauge inspection tool must be used. This is to be sure they are
properly drawn up (tightened).
Do not attempt to remove or tighten a fitting with the fuel system
under pressure.
Surface finish of the fuel tube is very important for proper sealing.
Fuel tubes that are oval shaped, have any depressions, heavy
scratches or raised portions should not be used.
Never attempt to force a fuel tube into a fitting or ferrule. The fuel
tube should fit easily into fittings/ferrules if they are not damaged.
The fuel tubes on the CNG system are under extreme high-pressure.
Never use steel, copper, brass or any other material as a substitute
for the original seamless stainless steel fuel tubes.
When removing/installing a fitting, always use a backup wrench on
the fitting body to prevent any fuel tube twist.
OPERATION
OPERATION
NOTE: Perform the fuel CNG fuel tube purging procedure. Refer to FUEL TUBE
PURGING - CNG.
High pressure stainless steel lines with a pre installed ferrule route the CNG to the fuel regulator. If service is
required, Replacement of the line with the original equipment is recommended.
Replace the steel lines if any of the following conditions are found:
Deterioration
Corrosion
Kinks
Fraying of braiding
Leaks
Damage
Chaffing

Check the lines for leaks using an air leak detection fluid.
MODULE, FUEL PUMP
DESCRIPTION
FUEL PUMP MODULE
The fuel pump module assembly is located on the top of the fuel tank . The complete assembly contains the
following components:
A combination fuel filter/fuel pressure regulator

A separate fuel pick-up, or inlet filter
An electric fuel pump
A lockring to retain pump module to tank
A soft gasket between tank flange and module
A fuel gauge sending unit (fuel level sensor)
Fuel line connection
The fuel gauge sending unit may be serviced separately. If the electrical fuel pump, primary inlet filter, fuel
filter or fuel pressure regulator require service, the fuel pump module must be replaced.
OPERATION
OPERATION
Refer to MODULE, FUEL PUMP, FILTER, FUEL, REGULATOR, FUEL PRESSURE and SENDING
UNIT AND SENSOR, FUEL LEVEL .
REMOVAL
REMOVAL

Fig. 141: Battery

must be released.


NOTE: Prior to removing the fuel pump module, use compressed air to remove
any accumulated dirt and debris from around fuel tank opening.
CAUTION: An indexing arrow is located on top of the main fuel pump module to
clock it's position into the fuel tank, note it's location for reassembly.
4. Position the lock ring remover/installer (special tool #9340, SAE Fuel Pump Lock Ring Wrench) (3) into
6. Rotate the breaker bar counterclockwise and remove the lock ring.
CAUTION: Whenever the fuel pump module is serviced, the rubber O-ring seal
must be replaced.
7. Remove the fuel pump module (4) from the fuel tank. Be careful not to bend float arm during removal.
8. Remove and discard the rubber O-ring seal.
INSTALLATION
INSTALLATION

CAUTION: An indexing arrow is located on top of the main 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.
1. Using a new rubber O-ring seal, position the fuel pump module into the fuel tank opening.
2. Position the lock ring (5) over top of the fuel pump module.
3. Rotate the fuel pump module until the embossed alignment arrow points to the center alignment mark or
the same position as noted during removal. This step must be performed to prevent the float from
contacting the side of the fuel tank.
4. Install the lock ring remover/installer (special tool #9340, SAE Fuel Pump Lock Ring Wrench) (3) into
6. Rotate the breaker bar clockwise until all seven notches of the lock ring have engaged.
7. Install the fuel tank. Refer to TANK, FUEL, INSTALLATION .

Fig. 145: Battery


RAIL, FUEL
OPERATION
OPERATION
The fuel rail is used as a distribution device to supply high-pressure fuel to the high-pressure fuel injectors.
REMOVAL
CNG
NOTE: Clean the top side of the engine area so that no debris can enter the open ports
of the throttle body or the fuel injectors.

Fig. 146: Clean Air Tube, IAT Sensor Electrical Connector & Air Cleaner Housing
1. Perform the CNG fuel line purge and gasoline fuel system pressure release. Refer to FUEL TUBE
PURGING - CNG and FUEL SYSTEM PRESSURE RELEASE .
2. Disconnect the battery negative cable.
4. Remove the clean air tube (1) and the air cleaner housing cover (3) as an assembly at the throttle body.
The factory fuel injection electrical harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position
identification. If the electrical harness is not tagged, note the injector position before electrical harness
removal.
5. Disconnect the electrical connectors at all sixteen fuel injectors. For the CNG injectors, require pressing
in the tang to remove. For the gasoline, push the slider away from the injector (1) while pushing slider,
depress tab (2) and remove the electrical connector (3) from the injector.

6. Remove the breather hose (3) at the oil fill housing and position aside.
7. Disconnect the PCV hose (1) and position aside to gain access to the fuel rail.
WARNING: The fuel system is under constant pressure even with engine off.
Before servicing the fuel rail, fuel system pressure must be released.
Fig. 148: CNG Fuel Rail Pressure Sensor, Fuel Rail & Fuel Supply Line

8. Disconnect the fuel rail sensor electrical connector (1).

9. Remove the CNG fuel supply line at the fuel rail (4).
11. Using a side to side motion, gently rock the right fuel rail (2) while pulling up until all four right side fuel
removal.
Fig. 149: Fuel Rail, Injectors & Fasteners

13. If the fuel injectors (4) are to be removed from the fuel rail (1). Refer to INJECTOR(S), FUEL,
REMOVAL .
CNG - GASOLINE

1. Perform the CNG line purge. Refer to FUEL TUBE PURGING - CNG .

5. Remove the clean air tube (1) and the air filter cover (3) as an assembly from the throttle body.


6.
7. Disconnect the electrical connectors at all sixteen fuel injectors. Push the slider away from the injector (1)
while pushing slider, depress tab (2) and remove the electrical connector (3) from the injector.

8. Disconnect the breather air hose (3) and position aside.
Disconnect the PCV hose (1) and position aside.
9. Disconnect the fuel rail sensor electrical connector (1).

10. Remove the CNG fuel supply line at the fuel rail (4).
11. Remove the CNG fuel rail mounting bolts (3) from both the left and right fuel rails (2).
13. Disconnect the gasoline fuel line quick connect fitting (2) at the fuel rail. Refer to FITTING, QUICK
removal.
INSTALLATION
CNG


the installation.
fuel rail assembly.
2. Using suitable pliers, install the fuel injector retaining clip (3).

3. Install the fuel rail assembly (2) into the intake manifold using a side to side motion.
4. Install the Fuel rail bolts (3). Tighten the bolts to 5 N.m (44 in. lbs.).
5. Connect the fuel rail sensor electrical connector (1).
6. Install the CNG fuel supply line (4) onto the fuel rail.
7. Connect the fuel injectors electrical connectors.
NOTE: Standard gasoline engine shown in illustration. CNG engine similar.


9. Connect the PCV hose (1) to the PCV.
10. Install the air cleaner housing cover (3) and intake hose (1) to the throttle body.
12. Start the engine and check for fuel leaks using a air leak detection fluid.
CNG - GASOLINE


the installation.
2. Position the fuel rail assembly while aligning the injectors into the holes in the intake manifold.


5. Install the CNG fuel injector (4) into the fuel rail (1) using a side to side motion while pushing injector
into the fuel rail assembly.
6. Using suitable pliers, install the fuel injector retaining clip (3).

7. Install the fuel rail assembly (2) into the intake manifold using a side to side motion.
8. Install the Fuel rail bolts (3).
9. Connect the fuel rail sensor electrical connector (1).
10. Install the CNG fuel supply line (4) onto the fuel rail.
11. Connect the fuel injectors electrical connectors.

13. Connect the PCV hose (1) to the PCV.

14. Install the air cleaner housing cover (3) and intake hose (1) to the throttle body.
16. Start the engine and check for fuel leaks using a air leak detection fluid.
RECEPTACLE, FUEL FILL
DESCRIPTION
DESCRIPTION
If the one-way check valve in the filler receptacle is found to be faulty. The filler receptacle must be
replaced as an assembly if any repairs are needed.


NOTE: It is recommended that the O-ring (1) located in the NGV1 should be inspected
for wear, damage or even missing at every fill up and replaced at every 16, 000
miles to decrease the chance of natural gas leaking past the fill nozzle.
The CNG filler receptacle (4) is located behind the fuel fill door. The receptacle houses a replaceable 50 micron
prefilter (3) and a one-way check valve (7). Replacing of the filter requires the O-ring (1) and the snap ring (2)
to be removed.
When the natural gas enters the system the opposing pressure forces the check valve (7) open. When the flow
stops the spring (8) forces the valve back onto a seat (6).
The check valve is held closed by a spring and back pressure created from the natural gas is the system.
REMOVAL
REMOVAL
1. Perform CNG system purging. Refer to FUEL TUBE PURGING - CNG .

2. Remove the upper cylinder tank cover (2).
Fig. 166: CNG Filler & Lock Nut


3. Remove the CNG filler (2) lock nut (1).

4. Remove the filler line (5) from the one way check valve at the quarter turn valve (2).

Fig. 168: Line, Grommet & Inner Fender

5. Remove the rubber grommet (2) from the inner fender (4).
6. Using care, remove the line (3) from the access hole at the fender.
INSTALLATION
INSTALLATION
Fig. 169: Line, Grommet & Inner Fender

1. Using care, route the filler line (3) through the access hole at the fender (4).
2. Install the rubber grommet (2) onto the inner fender.

Fig. 170: CNG Filler & Lock Nut

3. Align the filler receptacle (2) to the fuel shroud.

4. Install the CNG filler lock nut (1). Tighten to 45 N.m (33 ft. lbs.).

5. Install the filler line (5) to the one way check valve at the quarter turn valve (2). Tighten the line to 5 N.m
(44 in. lbs.).
6. Check the fuel lines for leaks using an air leak detection fluid.
7. Install the upper cylinder tank cover (2).
REGULATOR, FUEL PRESSURE
DESCRIPTION
DESCRIPTION
The fuel pressure regulator is located in the fuel pump module assembly and is non-serviceable.
DESCRIPTION - CNG PRESSURE REGULATOR
The fuel pressure regulator for the CNG is located in the engine compartment on the bulk head, to the right side
of the engine assembly.
OPERATION
OPERATION - CNG

Fig. 173: CNG Pressure Regulator

The regulator (2) reduces the pressure to the fuel rail in two stages. The first stage (7) will reduce the high
pressure supply from the cylinder tanks down to 230 PSI The second stage (1) will reduce the 230 PSI down to
163 PSI.
When the fuel pressure is reduced. The CNG internal of the regular can rapidly cool down, even freeze. To
regulate the CNG temperature. There are passages through-out the regulator that allow engine coolant to pass
through. Introduction engine coolant to the regulator will help insure that the regulator doesn't malfunction due
to freezing.
The regulator contains a electronically controlled shut off valve (2) The device is used only as a safety and
does not effect fuel system operation. The valve controls the flow of CNG through the regulator. The valve
will stay closed stopping the flow into the regular. When energized from the CNG control relay, the valve opens
allowing the fuel to flow.
The CNG control relay gets its power from the Automatic Shut Down (ASD) relay circuit. The control allows
the power to the cylinder valves to energize (open) and the pressure regulator valve to energize (open).
The Pressure Regulator Assembly consist of:
Low Side Pressure Regulator

Electronically Controlled Shut Off Valve
High Pressure Sensor
Internal Filter

Venting Valves
Pressure Relief Valve
High Side Pressure Regulator
Engine Coolant Passages
Solenoid Valve Electrical Connector
REMOVAL
CNG REMOVAL
1. Perform the CNG fuel system purge. Refer to FUEL TUBE PURGING - CNG .
2. Disconnect the IAT sensor (2)
3. Remove the air cleaner upper cover (3) and clean air tube (1) at the throttle body as an assembly.
4. Remove the lower air cleaner housing assembly.

Fig. 175: Remove/Install Lower Housing

5. Remove the lower air cleaner housing mount (2).
Fig. 176: Inner Fender & PCM Bracket


6. Remove the PCM bracket (2) from the inner fender (1) and position aside.
Fig. 177: CNG High Pressure Regulator, High Pressure Line & Shut-Off Relay

8. Disconnect the CNG shut-off relay (3).
9. Remove the high pressure line (2) from the regulator (1).

Fig. 178: CNG High Pressure Regulator & High Side Inlet Fitting
10. If required, remove the high side inlet fitting (1) from the pressure regulator (2).

11. Remove the filter from the inlet fitting.


12. Disconnect the high pressure sensor electrical connector (3).

13. Disconnect the high pressure shut down solenoid electrical connector (9).
14. Lower the cooling system to the proper level.
15. Remove the cooling lines at the regulator (8).

Fig. 181: Regulator Mount, Regulator & Nuts

16. Remove the low pressure supply line at the fuel rail.
17. Remove the nuts (3) that mount the regulator (2) to the bulkhead.
Fig. 182: Regulator, Low Side Supply Line, Bracket & Bolts

18. Remove the bolts (4) that mount the regulator (1) to the bracket (3).
19. Remove the low side supply line (2).
Fig. 183: Pressure Regulator & Low Side Elbow

20. If required, remove the low side elbow (2) from the pressure regulator (1).
INSTALLATION
CNG INSTALLATION


1. If removed, install the high side filter into the inlet fitting.
Fig. 185: CNG High Pressure Regulator & High Side Inlet Fitting
2. Install the inlet fitting (1) into the regulator (2). Tighten to 42 N.m (31 ft. lbs.).

Fig. 186: Pressure Regulator & Low Side Elbow

3. If removed, install the elbow into the low side out put. Tighten to 73 N.m (54 ft. lbs.).
Fig. 187: Regulator, Low Side Supply Line, Bracket & Bolts

4. Position the regulator (1) to the mounting bracket (3).

5. Install the regulator to bracket bolts. Tighten to 21 N.m (16 ft. lbs.).
6. Loosely install the low pressure line (2) to the pressure regulator (1).
Fig. 188: Regulator Mount, Regulator & Nuts

7. Position the regulator assembly (2) onto the bulkhead by guiding the bracket tab (1) into the inner fender.
8. Install the mounting nuts (3). Tighten to 9 N.m (80 in. lbs.).
9. Tighten the low pressure supply line to 45 N.m (33 ft. lbs.).

Fig. 189: CNG High Pressure Regulator, High Pressure Line & Shut-Off Relay
10. Install the high pressure supply line (2). Tighten line to 45 N.m (33 ft. lbs.).
11. Connect the CNG shut-off relay (3) electrical connector.

12. Connect the electrical connector to the high pressure sensor (3).
13. Connect the high pressure shut down solenoid electrical connector (9).
14. Install the cooling lines at the pressure regulator (8).
Fig. 191: Inner Fender & PCM Bracket

15. Position the PCM bracket (2) to the inner fender (1).

Fig. 192: Remove/Install Lower Housing

16. Position the air housing mount (2) to the inner fender.
17. Align the mount to the PCM bracket. Tighten the air cleaner housing mount bolts (1) to 10 N.m (89 in.
lbs.).

18. Install the lower air cleaner housing assembly.

19. Install the upper air cleaner cover (3) and clean air tube (1) assembly.
21. Fill the CNG lines.
22. Checked the CNG system for leaks using an air leak detection fluid.
RELAY, FUEL PRESSURE SHUT-OFF
DESCRIPTION
DESCRIPTION
The shut-down relay in located on the lower left side of the CNG pressure regulator bracket.
OPERATION
OPERATION
The shut-off solenoid relay is used in place of the conventional fuel pump relay. It is used to electrically control
operation of the high-pressure fuel shut-off solenoid. The solenoid is located within the fuel pressure regulator
and the manual control valves on the cylinder tanks.
The Powertrain Control Module (PCM) operates the high-pressure fuel shut-off solenoid relay through a ground
path.
The PCM turns the ground path off when the ignition switch is in the OFF position. When the ignition switch is
in the ON or CRANK position, the PCM monitors the crankshaft position sensor and camshaft position sensor
signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive the necessary
crankshaft position sensor and camshaft position sensor signals when the ignition switch is in the Run position
(indicating the engine has not started and is not running), it will de-energize the relay.
REMOVAL
REMOVAL

Fig. 194: Fuel Pressure Regulator Bracket, Shut-Off Relay & Nut

2. Disconnect the shut-down relay (2) electrical connector.
3. Remove the nut (3) from the pressure regulator bracket (1).
4. Remove the relay from the vehicle.
INSTALLATION
INSTALLATION

Fig. 195: Fuel Pressure Regulator Bracket, Shut-Off Relay & Nut
1. Position the shut-down relay (2) onto the fuel pressure regulator bracket (1).
2. Install the nut (3). Tighten to 10 N.m (89 in. lbs.).
3. Reconnect the shut-down relay electrical connector.
4. Check condition of relay terminals and Fuse and Relay Block connector terminals for damage or
corrosion. Repair if necessary before installing relay.
5. Reconnect the battery negative cable.
DESCRIPTION
DESCRIPTION
The fuel gauge sending unit (fuel level sensor) is attached to the fuel pump module. The sending unit consists of
a float, an arm, and a variable resistor track (card).
The sensor is non-servicable. If replacement is necessary, the fuel pump module assembly must be replaced.
SENSOR, FUEL PRESSURE
DESCRIPTION
DESCRIPTION

The CNG utilizes two separate fuel pressure sensor. The high pressure sensor or cylinder tank pressure sensor is
located on the top left side of the fuel pressure regulator.
The low side pressure sensor is part of the fuel rail sensor that is located on the CNG fuel rail.
OPERATION
OPERATION
The fuel tank pressure sensor reads the pressure from the cylinder tanks to the pressure regulator. The pressure
signal is used for determining the fuel level in the CNG fuel system.
The fuel rail sensor monitors the pressure entering the fuel rail. The readings from the pressure and temperature
are sent to the PCM were it can regulate the CNG fuel to the injectors. The PCM can adjust the short term or
long term trim of the injectors depending on the information being received by the oxygen sensors. For the fuel
rail procedure, refer to SENSOR, FUEL RAIL .
REMOVAL
REMOVAL


1. Perform the fuel tube purging. Refer to FUEL TUBE PURGING - CNG.
2. Disconnect the tank sensor (3) electrical connector.
3. Remove the tank sensor from the pressure regulator (4).
INSTALLATION
INSTALLATION

1. Install the tank sensor (3) onto the pressure regulator (4).
2. Connect the electrical connector.
3. Pressurize the CNG system.
4. Check for leaks using an air leak detection fluid.
SOLENOID, HIGH PRESSURE FUEL SHUT-OFF
DESCRIPTION
DESCRIPTION


The high pressure fuel shut off solenoid (2) is located on the fuel pressure regulator (4).
OPERATION
OPERATION
The high-pressure fuel shut-off solenoid is used as an on/off valve to electrically control high-pressure gas
flowing through the fuel pressure regulator. It is operated by the Powertrain Control Module (PCM). The valve
is closed when there is no powered supplied to the valve. When the shut down relay energizes, the solenoid
valve opens.
The high-pressure fuel shut-off solenoid is a part of the fuel pressure regulator. To replace the solenoid, the fuel
pressure regulator assembly must be replaced. Refer to REGULATOR, FUEL PRESSURE, REMOVAL and
REGULATOR, FUEL PRESSURE, INSTALLATION .
TANK, FUEL
REMOVAL
REMOVAL

Fig. 199: Battery

must be released.


4. Perform the fuel tank draining procedure. Refer to DRAINING FUEL TANK .
5. Disconnect the electrical connector from ESIM switch (4).
6. Disconnect the quick-connect fitting at the front of the fuel tank (10).
7. Disconnect the quick-connect fitting (8) at the rear of the fuel tank.
8. Loosen the fill hose retaining clamp (9) at the rear of the fuel tank and disconnect the fill hose.
9. Using a suitable hydraulic jack with a fuel tank adapter, support the fuel tank.

10. Remove the two fuel tank support strap retaining nuts (5) and remove both fuel tank support straps (4).
11. Carefully lower the fuel tank a few inches and disconnect the fuel pump module electrical connector.
12. Disconnect the fuel line quick-connect fitting at the fuel pump module.
13. Lower the fuel tank and remove from hydraulic jack.
14. If fuel pump module removal is necessary. Refer to MODULE, FUEL PUMP, REMOVAL .
INSTALLATION
INSTALLATION


1. If fuel pump module installation is necessary. Refer to MODULE, FUEL PUMP, INSTALLATION .
2. Secure the fuel tank onto a suitable hydraulic jack with a fuel tank adapter.
3. Raise and position the fuel tank leaving room to make the connections at the top of the fuel tank.
4. Connect the fuel supply line (6) to the fuel pump module.
5. Connect the electrical connector (5) to the fuel pump module.


6. Raise the fuel tank (1) until snug to the body.

7. Install the fuel tank straps (4).
8. Install the strap nuts (5) and tighten to 41 N.m (30 ft. lbs.).
9. Remove the hydraulic jack.


10. Connect the electrical connector to the ESIM switch (4).

11. Connect the quick-connect fitting at the front of the fuel tank (10).
12. Connect the quick-connect fitting (8) at the rear of the fuel tank.
13. Connect the fill hose (7) at the rear of the fuel tank and securely tighten the fill hose retaining clamp (9).

Fig. 206: Battery


TUBE(S), FUEL
DESCRIPTION
DESCRIPTION
Also, refer to FITTING, QUICK CONNECT - STANDARD PROCEDURE .
off). Before servicing any fuel system hoses, fittings, lines, or most
components, fuel system pressure must be released. Refer to FUEL
SYSTEM PRESSURE RELEASE.
The lines/tubes/hoses used on fuel injected vehicles are of a special construction. This is due to the higher fuel
pressures and the possibility of contaminated fuel in this system. If it is necessary to replace these
lines/tubes/hoses, only those marked EFM/EFI may be used.
If equipped: The hose clamps used to secure rubber hoses on fuel injected vehicles are of a special rolled edge
construction. This construction is used to prevent the edge of the clamp from cutting into the hose. Only these
rolled edge type clamps may be used in this system. All other types of clamps may cut into the hoses and cause
high-pressure fuel leaks.

Use new original equipment type hose clamps.
TUBE, FUEL TANK FILLER
REMOVAL
REMOVAL
Fig. 207: Removing Capless Fuel Filler Locking Tab Cover

1. Using a flat blade screwdriver, remove the cap less fuel filler locking tab cover (1) by prying the cover
upwards and away from the support plate.

Fig. 208: Remove/Install Support Plate

2. Remove the support plate (2).
NOTE: Illustration shown without the filler tube, to show the tab locations.

Fig. 209: Removing Upper Locknut Housing

3. Insert two pocket screw drivers (2) in the side guide slots.
4. Push down on the locking tabs (1) enough to clear the upper lockout housing.
Fig. 210: Remove/Install Lockout Housing

5. Twist the outer Lockout housing (1) counter clockwise and remove from the filler tube (3).
6. Raise the vehicle.

Fig. 211: Ground Wire, Filler Neck & Fasteners

7. Remove the ground wire (5).

8. Remove the filler neck (3) to filler support bracket bolt (4).
Fig. 212: Remove/Install Filler Tube

9. Loosen the fuel filler tube hose clamp (2) at the fuel tank hose (3).
10. Disconnect the fuel breather tube (6) from the fuel tank pressure sensor (4).
11. Remove the filler tube from the vehicle.
INSTALLATION
INSTALLATION
Fig. 213: Remove/Install Filler Tube

1. Position the filler tube (1) to the fuel tank filler hose (3).
2. Hand tighten the hose clamp (2).
3. Install the fuel breather tube (6) to the tank pressure sensor (4).

Fig. 214: Ground Wire, Filler Neck & Fasteners

4. Install the filler tube (3) to filler tube bracket bolt (4). Tighten the to 12 N.m (106 in. lbs.).
5. Install the screw (5) for the ground strap. Tighten the to 5 N.m (44 in. lbs.).
6. Lower the vehicle.

Fig. 215: Remove/Install Lockout Housing

7. Position the filler tube through the filler tube housing rubber grommet (3).
8. Install the cap-less housing (1) into the filler tube (2).
9. Twist the cap-less housing clockwise to lock into position.
Fig. 216: Remove/Install Support Plate

10. Install the support plate (2) onto the lockout housing (1).
11. Snap the locking tab cover onto the housing.
VALVE, FUEL CYLINDER CONTROL
DESCRIPTION
DESCRIPTION




The shut down solenoids are located in the manual valves on the CNG cylinder tanks.
OPERATION
OPERATION
The manual valves at the cylinder tanks house the emergency shut down solenoids. The solenoids remain closed
when de-energized. A relay located next to the fuel regulator, controls the applied voltage to the solenoid during
key on condition. When voltage is applied. The solenoid is energized allowing the valve to overcome the tank
pressure. When the valve is de-energized. A spring and tank pressure aid in sealing the valve against the valve
seat allowing for a secure seal.
When filling of the cylinder tank occurs. The pressure from the fill station will over come the one way valves
spring pressure, allowing the CNG to enter the tanks with out restriction.

VALVE, FUEL FILL CHECK
DESCRIPTION
DESCRIPTION

NOTE: The one-way check valves are non repairable. If the check valves are faulty.
They must be replaced.
Two different one-way check valves are used with the CNG fuel system. One of the valves is located integrally
within the fuel fill receptacle.
The one-way check valve (7) is part of the fuel fill receptacle. A spring (8) holds the valve against a seal (6).
The filler receptacle holds a 50 micron filter that is replaceable by removing the seal (1) and the snap ring (2).
The filter (3) can be removed with a small mechanics pick. For Installation/Removal procedures of the filler
receptacle. Refer to RECEPTACLE, FUEL FILL, REMOVAL.


The other one-way check valve (5) is located between the cylinder tank near the manual (master) shut-off valve
(2). For Installation/Removal procedures. Refer to VALVE, MANUAL SHUT-OFF, REMOVAL.
OPERATION
OPERATION
The one way check valve allows the on-coming fuel to pass through the receptacle. The valve closes when there
is no pressure introduced. Both valves are used to keep fuel from escaping from the fuel fill receptacle (fuel
supply will only travel toward fuel cylinders).
VALVE, MANUAL SHUT-OFF
DESCRIPTION
DESCRIPTION


A 1/4 turn, manual (master) (2) and the cylinder tanks shut-off valves (1, 4) are located in the cylinder tank
cover access hatch.
OPERATION
OPERATION

Fig. 221: 1/4 Turn Valve Positions

The 1/4 turn master turning valve is a ball style valve used as a first response safety device. The valve can be
easily be shut off by rotating the valve in a clockwise position so that the valve lever is parallel with the
cylinder tanks. When in the open position. The valve is parallel with the bracket that the valve is mounted to.
NOTE: The valves on the cylinder tanks are
NON REPLACEABLE
If a manual valve on the cylinder tank is in need or repair. The Cylinder tank
must be removed and then sent to a certified technician.
The manual valves that are located on the cylinder tanks also house the one-way check valve, which control the
CNG pressure. The pressure in the tank acts against the one-way check valve to keep the valve closed unless the
applied voltage acts upon the internal solenoid. The solenoid over comes the tank pressure to allow the CNG to
flow through out the fuel system. When the CNG cylinder tanks are being filled. The on coming pressure is able
to over come the one-way check valve allowing the cylinder tanks to be filled.
The manual valves on the cylinder tanks house built-in safety devices:
To insure there will not be an over charging of the tanks. A mechanical burst disc has been implemented. If the
tank pressure reaches 4800-5000 PSI. The pressure will over come the disc and vent the pressure back to the
proper tank capacity.
Also added to the valve is a thermally controlled valve. When the temperature of the valve reaches 110C°

(230F°). The vent's core will melt, allowing the CNG to vent from the tanks.
REMOVAL
REMOVAL
1. Perform CNG fuel tube purging. Refer to FUEL TUBE PURGING - CNG.
2. Remove the cylinder tank top cover (2).


3. Remove the screws (3) that support the valve to the valve bracket (2).
4. Remove the bolts (1) that secure the 1/4 turn valve bracket to the cylinder tank cages.
Fig. 224: 1/4 Turn Valve, T-Fitting, One Way Check Valve & Pressure Line

5. Remove the pressure line (4) from the forward cylinder tank.
6. Remove the line at the one way check valve located at the 1/4 turn valve (1).
7. Remove the filter supply line at the T-fitting (2).
8. Remove the filler line at the one way check valve (3).
INSTALLATION
INSTALLATION
Fig. 225: 1/4 Turn Valve, T-Fitting, One Way Check Valve & Pressure Line
1. Loosely install the front cylinder tank supply line (4) to the manual shut off valve.
2. Loosely install the filler line (3) to the one way check valve.
3. Loosely install the filter supply line at the 1/4 turn valve T-fitting (2).


4. Position the 1/4 turn valve mounting bracket (2).

5. Install the 1/4 turn valve screws (3). Tighten to 5 N.m (44 in. lbs.).
6. Install the cage bolts (1). Tighten the bolts to 21 N.m (16 ft. lbs.).
7. Using care, tighten the lines to 35 N.m (26 ft. lbs.).
8. Refill the CNG system.
9. Check the lines for leaks using an air leak detection fluid.

10. Install the top cylinder tank cover (2). Tighten the bolts (1) to 53 N.m (39 ft. lbs.).
RELAY, FUEL INJECTOR
DESCRIPTION
DESCRIPTION
The fuel injection relays are located on a mounting bracket above the CNG fuel pressure regulator.
OPERATION
OPERATION
Two separate relays control the fuel injectors. When the primary relay is on. The secondary relay is off. The
PCM controls the ground to the relays and determines when to switch the relays from the gasoline to CNG. This
allows for smooth fuel transfer and operation. The ASD relay supplies both unique relays with power.
REMOVAL
REMOVAL

Fig. 228: Fuel Injector Relay Electrical Connectors, Hood Light Wiring Harness Clip & Bracket Nuts
1. Disconnect the negative battery cable.

2. Disconnect the fuel injector relay electrical connectors (4).
3. Remove the hood light wiring harness clip (2) from the stud.
4. Remove the bracket nuts (3).
5. Remove the relay bracket assembly from the vehicle.

Fig. 229: Bracket, Nuts & Relays

6. Remove the nuts (2).

7. Remove the relays (3) from the bracket (1).
INSTALLATION
INSTALLATION

Fig. 230: Bracket, Nuts & Relays

1. Position the fuel injector relay (3) onto the relay bracket (1).
2. Install the nuts (2). Tighten to 6.8 N.m (60 in. lbs.).
Fig. 231: Fuel Injector Relay Electrical Connectors, Hood Light Wiring Harness Clip & Bracket

Nuts
3. If removed, position the relay bracket onto the bracket studs. Tighten nuts (3) to 9 N.m (80 in. lbs.).
4. Install the relay electrical connectors (4).
5. Install the hood light wiring retainer (2) to the stud.
FUEL INJECTION, CNG

WARNING
WARNING
ANY service that is required on the Compressed Natural Gas, purging of the fuel tube system must be
done . Refer to FUEL TUBE PURGING - CNG .
If a physical inspection of the CNG cylinder tanks is required. Refer to CYLINDER, FUEL, INSPECTION.
Any service required on the CNG cylinder tanks must be done by a certified CNG service technician .
WARNING: Before performing any service or repair on Compressed Natural Gas

(CNG) equipped vehicles, the following warnings and safety precautions
must be read and followed:
The CNG system should be serviced only by qualified natural gas

vehicle technicians
Natural gas vapors at atmospheric pressure are lighter than air and
will rise and disperse in open areas. In enclosed areas, natural gas
vapor may collect and form a combustible mixture. If the vehicle is
routinely placed in an enclosed area, the area should be provided
with adequate ventilation and/or a natural gas detection system. For
long term storage, the manual shutoff valve and each individual fuel
control valve should be closed.
A fire or explosion could result if a source of ignition or flame is
present with natural gas in a confined-unventilated area. Provide
proper ventilation when servicing CNG vehicles.
Natural gas contains an odor additive. Occasionally, mild natural gas
odors may be noticed during engine starting and after engine shut
down. This is because of small quantities of unburned gas in the
engine intake and exhaust manifolds. While these are normal, as are
gasoline odors in similar circumstances, a persistent odor of natural
gas indicates a leak is present. Have the vehicle checked
immediately for source of leak. If a leak is determined to exist, do not
bring the vehicle into an unventilated area.
Do not attempt to weld any part of the fuel cylinders or any other fuel

system component.
Do not attempt to modify any fuel system component or replace any
component with parts that do not meet Chrysler corporation
requirements.
Do not apply any paint or undercoating material to any fuel system
component.
Do not attempt to force open or tamper with any fuel tubes or valves.
A sudden release of high-pressure gas may occur resulting in bodily
injury.
Do not park or service vehicle near any source of excessive heat or
open flames.
Do not use a paint oven to cure any paint repairs as CNG fuel
cylinders on these vehicles are equipped with pressure relief safety
devices. These devices will vent to the atmosphere at approximately
103°C (217°F).
When a vehicle has been involved in an accident which may have
caused damage or dislocation to the CNG system, the system
should be inspected and pressure tested. This should be done
before being returned to service.
Any fuel system component, including the cylinders, that have been
subjected to fire, may not be returned to service due to reduced
pressure capability.
U.S. Requirements: Each CNG fuel cylinder manufactured on or after
March 27, 1995 must be removed and reinspected after a motor
vehicle accident or fire and at least every 36 months or 36, 000 miles
(whichever comes first) for damage and deterioration in accordance
with Motor Vehicle Safety Standard No. 304 Compressed Natural Gas
Fuel Containers And Compressed Gas Association (CGA), Arlington,
VA. Guidelines C-6.4. Retest markings must be stamped on the
cylinder neck or marked on a label securely affixed to the cylinder
and overcoated with epoxy near the original test date. Reheat
treatment or repair of rejected cylinders is not authorized. The fuel
cylinder expires and must be removed from service fifteen years
from the date of manufacture. A label on the fuel filler door states
the cylinder expiration date. A similar label is attached to each fuel
cylinder. If there is a question about the proper inspection of the
CNG cylinder, contact the manufacturer as identified on the cylinder
label.
Canadian Requirements: The cylinder must be reinspected after a
motor vehicle accident or fire and at least every 36 months or 36, 000
miles (whichever comes first) for damage and deterioration in
accordance with Canadian Standards Association (CSA) B51-97,
Part 2 High-Pressure Cylinders For The Onboard Storage Of Natural
Gas As A Fuel For Automotive Vehicles And Compressed Gas

Association (CGA), Arlington, VA. Guidelines C-6.4. Retest dates

must be stamped on the exposed metallic surface of the cylinder
neck or marked on a label securely affixed to the cylinder and
overcoated with epoxy near the original test date. Reheat treatment
or repair of rejected cylinders is not authorized. The fuel cylinder
expires and must be removed from service fifteen years from the
date of manufacture. A label on the fuel filler door states the first
cylinder expiration date. It is recommended that the fuel system
components be inspected periodically for leaks and/or excessive
wear.
Fuel the vehicle using a NGV 1 certified fill nozzle as specified on the
label inside the fuel filler door. Do not attempt to fuel the vehicle with
any other type of nozzle
Before any part of the CNG fuel system is opened for repair, the
system must be purged of all natural gas. Refer to FUEL TUBE
PURGING - CNG.


NATURAL GAS.
WARNING: The first high pressure component to be serviced, must be loosened

slowly, so that the pressure inside the fuel system can adjust to ambient
pressure.

DIAGNOSIS AND TESTING - VISUAL INSPECTION - CNG
For Compressed Natural Gas (CNG) powered vehicles:
A visual inspection for loose, disconnected, or incorrectly routed wires and fuel tubes should be made. This
should be done before attempting to diagnose or service the fuel injection system. A visual check will help spot
these faults and save unnecessary test and diagnostic time. A thorough visual inspection will include the
following checks:
1. Be sure manual 1/4 turn gas shut-off valve is open. Valve handle should be parallel with fuel cylinders (or
fuel line).
2. Be sure the fuel (manual) control valves on all 4 fuel cylinders are fully open. Valves are fully opened
when turned fully counterclockwise.
3. Be sure electrical connector at low-pressure fuel shut-off solenoid is connected, clean and tight.
4. A pigtail wiring harness connects high-pressure fuel shut-off solenoid to main chassis wiring harness. The
pigtail connection is made above and to rear of left-side mounted fuel cylinders near manual shut-off
valve. Be sure this electrical connection is secure, clean and tight.
5. Be sure electrical connectors at fuel pressure and fuel temperature sensors are connected, clean and tight.
6. Verify that the three 32-way connectors are fully inserted into connectors of Powertrain Control Module
(PCM).
7. Inspect battery cable connections. Be sure that they are clean and tight.
8. Inspect Automatic Shut-down (ASD) relay. The ASD relay is located in the Power Distribution Center
(PDC). The PDC is located in engine compartment. Inspect relay connections. Inspect relay for signs of
physical damage and corrosion.
9. Inspect high-pressure fuel shut-off solenoid relay. Relay is located in the Fuse Block at the left end of
instrument panel. Inspect relay connections. Inspect relay for signs of physical damage and corrosion.
10. Inspect starter motor relay connections.
11. Inspect ignition coil connections. Verify that coil secondary cable is firmly connected to coil.
12. Verify that distributor cap is correctly attached to distributor. Be sure that spark plug cables are firmly
connected to distributor cap and spark plugs are in their correct firing order. Be sure that coil cable is
firmly connected to distributor cap and coil. Be sure that camshaft position sensor pigtail harness
connector (at distributor) is firmly connected to engine harness connector. Inspect spark plug condition.
Connect vehicle to an oscilloscope and inspect spark events for fouled or damaged spark plugs or cables.
13. Inspect fuel tubes (lines) for any damage or for being kinked.
14. Inspect all fuel tube (line) connections for leaks. Refer to DIAGNOSIS AND TESTING - TESTING
FOR FUEL LEAK - CNG .
15. Verify that generator output wire, generator connector and ground wire are firmly connected to generator.
16. Inspect system body ground connections for being loose, dirty or corroded. Refer to appropriate Wiring
Diagrams information for location of ground connections.
17. Verify positive crankcase ventilation (PCV) valve operation. Verify PCV valve hose is firmly connected
to PCV valve and manifold.

18. Verify that hose connections to all ports of vacuum fittings on intake manifold are tight and not leaking.
19. Inspect accelerator cable, transmission throttle cable and cruise control cable connections, if equipped.
Check their connections to throttle arm of throttle body for any binding or restrictions.
20. Verify that vacuum booster hose is firmly connected to fitting on intake manifold. Also check connection
to brake vacuum booster.
21. Inspect air cleaner inlet and air filter element for dirt or restrictions.
22. Inspect radiator grille area, radiator fins and air conditioning condenser (if equipped) for restrictions.
23. Verify that intake manifold air temperature sensor wire connector is firmly connected to harness
connector.
24. Verify that MAP sensor electrical connector is firmly connected to MAP sensor. Also verify that rubber
nipple from MAP sensor to throttle body is firmly connected.
25. Verify that fuel injector wire harness connectors are firmly connected to injectors in the correct firing
order. Each harness connector is numerically tagged (INJECTOR #1, INJECTOR #2 etc.) with its
corresponding engine cylinder number.
26. Verify harness connectors are firmly connected to idle air control motor and throttle position sensor
(TPS).
27. Verify that wire harness connector is firmly connected to engine coolant temperature sensor.
28. Inspect for exhaust system restrictions such as pinched exhaust pipes, collapsed muffler or plugged
catalytic convertor.
29. Verify that electrical harness is firmly connected to neutral safety switch.
30. Verify electrical harness is firmly connected to rear wheel speed sensor. Verify rear wheel speed sensor is
firmly attached to rear axle with proper air gap. Refer to ANTILOCK BRAKE SYSTEM (ABS) -
SERVICE INFORMATION - RAM PICKUP for information.
31. If equipped with 4-wheel antilock brake system, verify electrical harness is firmly connected to each front
wheel speed sensor. Verify both front wheel speed sensors are firmly attached. Refer to ANTILOCK
BRAKE SYSTEM (ABS) - SERVICE INFORMATION - RAM PICKUP for information.
32. Inspect transmission torque convertor housing for damage to timing ring on drive plate/flywheel.
33. Verify firm connection of electrical connector at top of fuel gauge pressure sensor (transducer or sending
unit). Sensor is attached to a fuel control valve located at rear of side mounted fuel cylinders.
34. Verify that battery cable and solenoid feed wire connections to starter solenoid are tight and clean. Inspect
for chaffed wires or wires rubbing up against other components.
INJECTOR(S), FUEL
DESCRIPTION
DESCRIPTION

Fig. 232: CNG-Style Fuel Injector

The Compressed Natural Gas (CNG) style fuel injectors and the standard gasoline style fuel injector work and
perform the same. Both injectors utilizes:
Upper O-ring
Electrical Connector
Body Externally and Internally
Lower O-ring
The CNG injectors have a more noticeable internal ticking do to the absence of a liquid, to aid in muffling the
internal solenoid. This is considered normal injector operation.
The CNG injector pulse width stays energized longer in order to maintain the proper engine performance.
Especial during the liquid fuel side switching over to CNG fuel side.
OPERATION
FUEL INJECTOR


1 - FUEL INJECTOR
2 - NOZZLE
3 - TOP (FUEL ENTRY)
The top (fuel entry) end of the injector (1) is attached into an opening on the fuel rail.
The fuel injectors are electrical solenoids. The injector contains a pintle that closes off an orifice at the nozzle
end. When electric current is supplied to the injector, the armature and needle move a short distance against a
spring, allowing fuel to flow out the orifice. Because the fuel is under high pressure, a fine spray is developed in
the shape of a pencil stream. The spraying action atomizes the fuel, adding it to the air entering the combustion
chamber.
The nozzle (outlet) ends of the injectors are positioned into openings in the intake manifold just above the
intake valve ports of the cylinder head. The engine wiring harness connector for each fuel injector is equipped
with an attached numerical tag (INJ 1, INJ 2 etc.). This is used to identify each fuel injector.
Battery voltage is supplied to the injectors through the ASD relay.
The PCM determines injector pulse width based on various inputs.
PCM OUTPUT
The nozzle ends of the injectors are positioned into openings in the intake manifold just above the intake valve
ports of the cylinder head. The engine wiring harness connector for each fuel injector is equipped with an
attached numerical tag (INJ 1, INJ 2 etc.). This is used to identify each fuel injector with its respective cylinder
number.

Battery voltage (12 volts +) is supplied to the injectors through the ASD relay. The ASD relay will shut-down
the 12 volt power source to the fuel injectors if the PCM senses the ignition is on, but the engine is not running.
This occurs after the engine has not been running for approximately 1.8 seconds.
The PCM determines injector on-time (pulse width) based on various inputs.
REMOVAL
5.7L

1 - PLIERS
2 - INJECTOR CLIP
1. Remove the fuel rail assembly. Refer to RAIL, FUEL, REMOVAL .

2. Using suitable pliers (1), remove the fuel injector retaining clip (2).
3. Remove the fuel injector (3) from the fuel rail (4) using a side to side motion while pulling the injector
out of the fuel rail assembly.

INSTALLATION
5.7L

1 - PLIERS
2 - INJECTOR CLIP
the installation.
fuel rail assembly.
2. Using suitable pliers (1), install the fuel injector retaining clip (2).
3. Install the fuel rail assembly. Refer to RAIL, FUEL, INSTALLATION .
4. Start the engine and check for fuel leaks.
SENSOR, FUEL RAIL
DESCRIPTION

DESCRIPTION
The temperature and the low side pressure are combined in a single sensor call the fuel rail sensor. The sensor is
located on the right side of the CNG fuel rail.
OPERATION
OPERATION
The fuel rail sensor reads the oncoming temperature of the CNG fuel entering the fuel rail. The information is
sent to the Powertrain Control Module (PCM) were it will calculate the temperature and pressure readings for
the required fuel injection timing.
REMOVAL
REMOVAL
WARNING: Refer to FUEL INJECTION, CNG, WARNING.
Fig. 236: CNG Fuel Rail & Fuel Rail Sensor

1. Perform the CNG fuel tube purging. Refer to FUEL TUBE PURGING - CNG.


3. Disconnect the fuel rail sensor (2) electrical connector.
4. Remove the sensor from the fuel rail (1).
INSTALLATION
INSTALLATION
Fig. 237: CNG Fuel Rail & Fuel Rail Sensor

1. Install the fuel rail sensor (2).

2. Connect the electrical connector.
FUEL DELIVERY, 6.7L DIESEL

DESCRIPTION
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 180, 000
kPa (26, 107 psi). Use extreme caution when inspecting for high-pressure
fuel leaks. Inspect for high-pressure fuel leaks with a sheet of cardboard.
High fuel injection pressure can cause personal injury if contact is made

with the skin.
The fuel system used on the Cummins engine is an electronically controlled, Bosch HPCR (High-Pressure
Common Rail) system. The HPCR system consists of five main components:
Electric Fuel Transfer (lift) Pump Located in the Fuel Tank

Fuel Pump/Gear Pump (attached to fuel injection pump)
High-Pressure Fuel Injection Pump
Fuel Injection Rail
Fuel Injectors
Also to be considered as part of the overall fuel system are:
Accelerator Pedal
Air Cleaner Housing/Element
Check Valve Banjo Fitting at Rear of Cylinder Head
Fuel Connector Tubes
Fuel Drain Manifold (passage)
Fuel Drain Valve (at filter)
Fuel Filter/Water Separator
Fuel Heater
Fuel Heater Relay
Fuel Transfer Pump Relay
Fuel Level (gauge) Sending Unit
Fuel Pressure Limiting Valve
Fuel Tank
Fuel Tank Module (containing a fuel gauge sending unit, separate fuel filter located at bottom of tank
module, and fuel transfer pump)
Fuel Tank Filler/Vent Tube Assembly
Fuel Tank Filler Tube Cap
Fuel Tubes/Lines/Hoses
High-Pressure Fuel Injector Lines
In-Tank Fuel Filter (at bottom of fuel tank module)
Low-Pressure Fuel Supply Lines
Low-Pressure Fuel Return Lines
Overflow Valve
Quick-Connect Fuel Line Fittings
Accelerator Pedal Position Sensor (APPS) Located in Cab
Water Draining (maintenance)

Water-In-Fuel (WIF) Sensor

Screened Banjo Bolt (22)
The fuel injection pump supplies high pressure to the fuel rail independent of engine speed. This high pressure
fuel is then accumulated in the fuel rail. High pressure fuel is constantly supplied to the injectors by the fuel rail.
The Engine Control Module (ECM) controls the fueling and timing of the engine by actuating the injectors.
Fuel enters the system from the electric fuel transfer (lift) pump, which is located inside of the fuel tank and
attached to the fuel tank module (the fuel transfer pump is no longer attached to the engine). Fuel is forced
through the fuel filter element and then enters the Fuel Pump/Gear Pump, which is attached to the rear of the
fuel injection pump. The Fuel Pump/Gear Pump is a low-pressure pump and produce pressures ranging from
551.5 kPa (80 psi) to 1241 kPa (180) psi. Fuel then enters the fuel injection pump. Low pressure fuel is then
supplied to the FCA (Fuel Control Actuator).
The FCA is an electronically controlled solenoid valve. The ECM controls the amount of fuel that enters the
high-pressure pumping chambers by opening and closing the FCA based on a demanded fuel pressure. The FPS
(Fuel Pressure Sensor) on the fuel rail monitors the actual fuel pressure and provides it as an input to the ECM.
When the actuator is opened, the maximum amount of fuel is being supplied to the fuel injection pump. Any
fuel that does not enter the injection pump is directed to the overflow valve. The overflow valve regulates how
much excess fuel is used for lubrication of the pump and how much is returned to the tank through the drain
manifold.
Fuel entering the injection pump is pressurized to between 200-1800 bar (2900-26107 psi) by three radial
pumping chambers. The pressurized fuel is then supplied to the fuel rail.
STANDARD PROCEDURE
WATER DRAINING AT FUEL FILTER HOUSING
Fig. 238: Identifying Drain Valve, Drain Hose, Mounting Screws, Sensor Harness Connector & Filter

Housing
The housing drain valve (4) serves two purposes. One is to partially drain the filter housing of excess water.
The other is to drain the housing for fuel filter or Water In Fuel (WIF) sensor replacement.
The filter housing (1) should be partially drained whenever the WIF warning lamp remains illuminated. (Note
that lamp will be illuminated for approximately two seconds when ignition key is initially placed in ON position
for a bulb check).
1. A drain hose (6) is located at the bottom of drain valve. Place drain pan under drain hose.
2. With engine not running, Route the fuel drain hose to an appropriate container and rotate drain valve (4)
one quarter turn counter clockwise to open it. Also loosen the fuel filter housing cover a 1/2 turn and
allow the fuel to drain from the fuel filter housing for two minutes. Rotate the drain valve (4) clockwise
one quarter turn to close it.
DIESEL FUEL SYSTEM CLEANING PROCEDURE
CAUTION: Cleanliness cannot be overemphasized when handling or replacing diesel

fuel system components. This especially includes the fuel injectors, high-
pressure fuel lines and fuel injection pump. Very tight tolerances are used
with these parts. Dirt contamination could cause rapid part wear and
possible plugging of fuel injector nozzle tip holes. This in turn could lead
to possible engine misfire. Always wash/clean any fuel system component
thoroughly before disassembly and then air dry. Cap or cover any open
part after disassembly. Before assembly, examine each part for dirt,
grease or other contaminants and clean if necessary. When installing new
parts, lubricate them with clean engine oil or clean diesel fuel only.
NOTE: Do not use any chemical cleaners or solvents on any fuel system lines or metal
components. Metal lines, rails and tubes have a coating that will be damaged by
these cleaners.
NOTE: Before cleaning the fuel system, perform the Lift Pump Flow test to determine if
the Lift Pump was damaged and will require replacement while the Fuel Tank is
out of the vehicle. The procedure and specifications can be found in the
CHECKING THE FUEL DELIVERY SYSTEM test procedure . Refer to DIAGNOSIS
AND TESTING, 6.7L .
1. Remove all of the steel fuel lines from the vehicle.

2. Flush tank to engine compartment bundle lines, supply and return, both directions.
3. Remove the fuel rail and remove the Pressure Limiting Valve (PLV) and pressure switch.
4. Submerge and soak all removed parts in clean diesel fuel.
5. Remove components from the diesel fuel and clean the inside and outside with compressed air.
6. Flush fuel rail with clean diesel and air. Both directions, multiple times.

7. Clean the PLV and pressure switch with compressed air.

8. Remove and flush out the Fuel Tank with clean diesel fuel. Wipe out the inside of the tank with a clean
cloth. Use an appropriate fuel container. Dispose of the contaminated fuel using the proper procedures.
Refer to TANK, FUEL, REMOVAL.
CAUTION: Dispose of petroleum based products in a manner consistent with all

applicable Local, State, Federal, and Provincial regulations.
9. Inspect the Lift Pump Module screen for extreme dirt accumulation. Clean/flush the Lift Pump Module.
Replace if necessary. (Most can be cleaned).
10. Install vent tubes on the rollover valves on the Fuel Tank to prevent water/dirt intrusion.
11. Reinstall the tank and 10 to 15 gallons of clean diesel fuel. Flash any controllers to the latest available
software version (PCM/TIPM/CCN). Refer to TANK, FUEL, INSTALLATION.
12. Clean fuel filter housing and install new (latest number available) Mopar Fuel Filter.
13. Pour half a bottle (approximately 15 ounces) of Mopar Diesel Fuel Injector Cleaner P/N 68194640AA
into the Fuel Tank with the clean fuel.
14. Warm engine while checking for leaks or running concerns. Correct concerns as necessary.
15. Drive the truck a short distance (parking lot) and stop several times to agitate the cleaner/fuel mixture in
the fuel tank. (Slosh fuel mixture in tank).
16. Monitor the scan tool and validate engine has reached operating temperature of 180°F (82°C).
17. Enable "Injector High Pressure Override" 3 times. This will stress the injectors and High Pressure
Delivery Pump and circulate the cleaner/fuel mixture through the entire system.
18. Safely drive truck somewhat aggressively. Perform three times, wide open throttle 0 to 60 hard
accelerations in a safe area to circulate cleaner and allow fuel to flush/clean injectors.
19. Verify repair by performing the Diesel Aftertreatment Validation - 6.7L procedure. Refer to DIESEL
AFTERTREATMENT VALIDATION- 6.7L .
FUEL SYSTEM PRIMING - DIESEL
A certain amount of air becomes trapped in the fuel system when fuel system components on the supply and/or
high-pressure side are serviced or replaced. Fuel system priming is accomplished using the electric fuel transfer
(lift) pump.
Servicing or replacing fuel system components will not require fuel system priming.
The fuel transfer (lift) pump is self-priming: When the key is first turned on (without cranking engine), the
pump operates for approximately 1 to 2 second and then shuts off (Note: When ambient temperatures are cold
enough to cause the intake air heaters to operate, the fuel lift pump will operate during the entire intake air pre-
heat cycle). The pump will also operate for up to 25 seconds after the starter is quickly engaged, and then
disengaged without allowing the engine to start. The pump shuts off immediately if the key is on and the engine
stops running.
1. Turn key to CRANK position and quickly release key to ON position before engine starts. This will

operate fuel transfer pump for approximately 25 seconds.

2. Crank engine. If the engine does not start after 25 seconds, turn key to OFF position, and leave it off for
at least 5 seconds. Repeat previous step until engine starts.
3. Fuel system priming is now completed.
4. Attempt to start engine. If engine will not start, proceed to following steps. When engine does start, it
may run erratically and be noisy for a few minutes. This is a normal condition.
CAUTION: Do not engage the starter motor for more than 30 seconds at a time.
Allow two minutes between cranking intervals.
5. Perform previous fuel priming procedure steps using fuel transfer pump. Be sure fuel is present at fuel
tank.
6. Crank the engine for 30 seconds at a time to allow fuel system to prime.
WARNING: The fuel injection pump supplies extremely high fuel pressure to each
individual injector through the high-pressure lines. Fuel under this
amount of pressure can penetrate the skin and cause personal injury.
Wear safety goggles and adequate protective clothing. Do not loosen fuel
fittings while engine is running.
WARNING: Engine may start while cranking starter motor.
DRAINING FUEL TANK
NOTE: Two different procedures may be used to drain fuel tank: using a diagnostic
scan tool to activate the fuel pump relay and drain the fuel tank, or remove the
fuel pump. Due to a one-way check valve installed into the fuel fill opening
fitting at the tank, the tank cannot be drained conventionally at the fill cap.
1. Disconnect the fuel supply line quick-connect fitting at the fuel filter. Refer to FITTING, QUICK
CONNECT .
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. Using a scan tool, activate the fuel
pump and drain the tank until empty.
NOTE: If electric fuel pump is not operating, fuel must be drained through fuel fill
fitting at tank. Refer to following procedures:
1. Disconnect the negative battery cable.

2. Remove the fuel pump module. Refer to MODULE, FUEL PUMP, REMOVAL.
3. After the fuel pump module has been removed, drain fuel tank into an approved diesel fuel draining
station.
DIESEL FUEL CONTAMINATION TESTING PROCEDURE
OVERVIEW
This procedure explains the proper method for extracting a fuel sample and specific methods to inspect for
contamination of any kind. The contamination we are looking for on the clean side of the Fuel Filter is very
small. We don't say dirt because it may be metal, water, plastic or any other contamination, other than clean
diesel fuel. The smallest we can see with naked eye is about 30 Microns. Our Fuel Filters have 5 Micron rating.
The only way we can see this size of contamination is to properly collect it and view it. The fuel sample needs
to be taken from the clean side of the system. In order to get a good clean side sample to inspect, perform the
following procedure exactly:
Required Equipment
ONE LITER GLASS MEASURING CUP
FOUR FEET OF CLEAR, FLEXIBLE TUBING, 5/16 ID (available at the local hardware)
MULTI-BULB LED FLASHLIGHT
HPDP FUEL RETURN HOSE
BRAKE CLEANER SPRAY
SELF LIGHTING MAGNIFIER (Optional)
All items used for collecting fuel MUST be cleaned with clean diesel fuel, brake clean, and air
ONLY. Failure to clean these items will contaminate the fuel sample. Do Not use towels to wipe out
the measuring cup.

Fig. 239: Clear Tubing, Flashlight & Measuring Cup

1. 5/16" CLEAR TUBING (20' Length)

2. MULTI-BULB LED FLASHLIGHT
3. 4 CUP (1 LITER) "PYREX" STYLE MEASURING CUP

Fig. 240: Locating Return Flow Quick Disconnect & Engine Fuel Drain Tube Connection
A. HPDP return flow quick disconnect (at front of Fuel Filter mount)
B. Engine fuel drain tube connection - All return flow to tank
DIAGNOSTIC TEST
1. CLEAN SIDE DIESEL FUEL SAMPLE COLLECTION AND INSPECTION
NOTE: The three photos in this test step illustrate the steps in this test procedure
for clarification.
NOTE: The fuel filter MUST NOT be removed or replaced prior to taking sample in
order to get accurate results.
NOTE: Warm the engine before collecting the fuel sample.
Start the engine and using a scan tool, monitor the Coolant Temperature Sensor reading in Data Display.

Fig. 241: Tilting Measuring Cup & Positioning Flashlight On Bottom Of Cup
1 LED FLASHLIGHT
2 MEASURING CUP
3 SLOWLY TILT THE CUP TOWARD YOU
1. While the engine is warming up, clean the clear tubing with clean diesel fuel and the glass
measuring cup using brake clean and compressed air only. Do not use a towel.
NOTE: Do not use brake clean or other chemicals on any vehicle parts for
the fuel handling system such as lines, pumps or fittings.
2. Monitor the scan tool until the vehicle has reached an operating temperature of 180°F (82°C).
3. Turn the engine off.
4. Remove the HPDP return line quick disconnect from the fitting located at the front of the Fuel
Filter housing at the banjo bolt joining the Pressure Limiting Valve return (Connection A in the fuel
system connections figure above).

NOTE: The fuel flowing from the return of the High Pressure Delivery Pump
(HPDP) MUST NOT be part of our sample. We are looking primarily
for injector return fuel. The easiest way is to eliminate the HPDP
return line and pull the injector return flow sample from the filter
mount, on the front side.
Fig. 242: Shining Flashlight Through Bottom Of Measuring Cup While Tilting Cup
LED FLASHLIGHT POINTING THROUGH BOTTOM OF CUP (Shine

1
Toward the Handle)
2 SLOWLY TILT THE CUP TOWARD YOU
5. Cap off the male fitting that the HPDP return line was disconnected from.
6. Disconnect the quick connect fitting for the fuel return line located on the back side of the Fuel
Filter housing (Connection B in the fuel system connections figure above).
7. Attach the four foot length of 5/16" clear tubing to this exposed male fitting and orientate it on a
downhill angle in to a drain pan. This will be your sample source hose.

8. Using a hose with two male fittings, attach one end to the HPDP return line disconnected in step 5.
Connect the other end to the fuel return line disconnected in step 7. This will return the High
Pressure Pump return flow back to the tank while collecting the sample.
9. Start the engine, and continue monitoring the coolant temperature to maintain the 180°F (82°C).
10. Using the scan tool, navigate to PCM > System Tests > Fuel Pressure Override Test and select
start.
11. Initiate the Fuel Pressure Override Test two consecutive times to further warm the fuel and allow
the tubing to be thoroughly rinsed clean.
12. Start the Fuel Pressure Override Test a third time. At mid stream of the test move the clear tube to
the measuring cup. Collect a sample of approximately 1/4 inch of fuel in the measuring cup.
13. Turn the engine off.
NOTE: Follow these next steps exactly to inspect the sample for
contamination.
Fig. 243: Locating Fuel Contamination In Measuring Cup


1 Contamination will gather at the trailing edge of fuel.

VIEW CAREFULLY, LOOKING FOR VERY SMALL PARTICULATE MATTER (May Look
Cloudy)
14. Allow the sample to sit for 10 minutes in a dust free environment to allow the debris to settle to the
bottom. It is important to not allow any air born contaminates to get into the fuel sample. Do
not shake, swirl, or agitate the fuel in any way. The contamination should settle to the bottom.
15. Hold the measuring cup (2) by the handle in one hand and shine the LED flashlight (1) through the
bottom of the container toward the handle of the cup.
16. Slowly tilt the measuring cup (2) toward you and keep the LED flashlight (1) at the trailing edge
of the fuel as it comes down the bottom of the cup and inspect for contamination.
Any dirt in the fuel will collect and be pulled by this trailing edge of fuel (Number one in
the last figure) . It may be any color and sometimes looks as though the fuel is cloudy. This
is the contamination. .
If you see ANYTHING AT ALL , the fuel is contaminated.
Is the fuel sample contaminated?
Yes
To ensure that the In Tank Lift Pump is operating properly, perform the Lift Pump Flow
Test. For instruction and specifications on this procedure, refer to CHECKING THE FUEL
DELIVERY SYSTEM , test step 5. After checking the In Tank Lift Pump operation,
perform the DIESEL FUEL SYSTEM CLEANING PROCEDURE .
Go To 2
No
Install new fuel filter and Mopar (CRC) fuel injector cleaner into the fuel tank at a ratio four
times the recommend concentration.
Go To 2
2. DIAGNOSTIC PATH
Were you instructed to inspect for Fuel Contamination from the MIL LIGHT ON PRETEST
PROCEDURE?
Yes
Perform the diagnostic trouble code test that was found to be present. Refer to DTC INDEX -
RAM PICKUP .
No
Go To 3

3. DIAGNOSTIC PATH CONTINUED
Were you instructed to inspect for Fuel Contamination from a Non-DTC TEST PROCEDURE?
Yes
Perform the DIESEL AFTERTREATMENT VALIDATION 6.7L procedure. Refer to DIESEL

AFTERTREATMENT VALIDATION- 6.7L .
No
Return to Diagnostic Test that directed you to inspect for fuel contamination.
SPECIFICATIONS
TORQUE - 6.7L
DESCRIPTION N.m Ft. Lbs. In. Lbs.

Charge Air Cooler Tube Clamp 14 - 124
Engine Cover Bolts 10 - 89
Fuel Filter Housing Cover 31 23 -
Fuel Filter Housing Bolts 24 18 -
Fuel Filter Housing Bolts
32 24 -
(secondary)
Fuel Filter Housing Bracket to
24 18 -
Engine Block Bolts
Fuel Injection Pump Drive Gear
8 - 71
Access Cover
Fuel Injection Pump Mounting
24 18 -
Nuts
Fuel Injection Pump-to-Gear
105 77 -
Shaft Nut
Fuel Injector Connector Retainer
15 - 133
Nut
Step 2 55 41 -
Fuel Line Quick Connect fitting at
24 18 -
Fuel Filter Housing Bracket
Fuel Pressure Limiting Valve (In
100 74 -
Fuel Rail)
Fuel Pressure Sensor 70 52 -
Fuel Rail Bolts 24 18 -
Fuel Tank Mounting Straps Bolts
61 45 -
(Mid-Ship)

Fuel Tank Mounting Bolts (Rear) 61 45 -

Fuel Tube Banjo Bolt in Back of
24 18 -
Cylinder Head
Fuel Tube Banjo Bolts at Fuel
24 18 -
Filter Housing Bracket
Fuel Tube Banjo Bolt at Fuel Rail 24 18 -
Fuel Return Tube Banjo Bolt at
24 18 -
Fuel Injection Pump
Fuel Tube Fitting (High-Pressure
40 30 -
Pump to Fuel Rail)
Fuel Tube Fitting (High-Pressure
40 30 -
- Cylinder Head to Rail)
Intake Manifold Bolts 24 18 -
Oil Dipstick Tube Bolt 24 18 -
Oil Dipstick Tube Nut 9 - 80
No. 6 Fuel Tube Shield Bolts 43 32 -
Rear Engine Lift Bracket Bolts 77 57 -
SPECIAL TOOLS
SPECIAL TOOLS
8978A - Decay Tool, Fuel

9340 - SAE Fuel Pump Lock Ring

Wrench
9327, 9327CC, 9397, 9575.)
L-4407A - Puller, Gear
FILTER, FUEL
DESCRIPTION
DESCRIPTION
Fuel filter 1 is located on the engine. Fuel filter 2 is located on the frame rail. The fuel filters protects the fuel
injection pump and fuel injectors by removing contaminates from the fuel.
REMOVAL
FUEL FILTER 1

Fig. 244: Fuel Filter Housing Cover

NOTE: Refer to VEHICLE QUICK REFERENCE - RAM PICKUP or the Owner's Manual for
recommended fuel filter replacement intervals.
1. Clean all debris from around filter canister (1) and canister cover.
2. Using a socket, rotate the fuel filter housing cover (1) counter clockwise and remove cover (1).
Fig. 245: Fuel Filter Element & O-Ring

3. Remove and discard the O-ring (2).

4. Remove fuel filter element (1).

FUEL FILTER 2
Fig. 246: Exploded View Of Secondary Fuel Filter

NOTE: Refer to VEHICLE QUICK REFERENCE - RAM PICKUP or the Owner's Manual for
recommended fuel filter replacement intervals.
1. Disconnect and isolate both negative battery cables.

2. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
3. Clean all debris from around the secondary fuel filter area.
4. Open the drain and drain fuel from fuel filter.
5. Disconnect the water in fuel sensor wire harness connector.
6. Remove the fuel drain/water in fuel sensor assembly (3).
7. Remove and discard the O-ring (2).
8. Remove fuel filter element (1).
INSTALLATION
FUEL FILTER 1

Fig. 247: Fuel Filter Element & O-Ring

CAUTION: Do not pre-fill the fuel filter with fuel. Severe damage to fuel system and
injection system components may result.
NOTE: The engine has a self-priming low-pressure fuel system. Refer to PUMP, FUEL
TRANSFER .
NOTE: DO NOT USE brake cleaner, carburetor cleaner, or similar harsh solvents for
cleaning the internal housing walls.
1. Ensure that the internal housing wall is clean of debris before installing a new fuel filter cartridge.
2. Install fuel filter element (1).
3. Lubricate with clean engine oil and install the new O-ring (2).

Fig. 248: Fuel Filter Housing Cover

4. Install the fuel filter housing cover (1) and tighten to 31 N.m (23 ft. lbs.).
Fig. 249: EVIC Switches

5. Once the fuel filter maintenance has been performed, the Fuel Filter Life monitor can be reset by:
Vehicle in RUN with engine OFF (no RPM)
Hold the right arrow (3) down to reset the monitor.
FUEL FILTER 2


1. Install the secondary fuel filter element (1) and tighten finger tight. Tighten the fuel filter an additional
1/2 turn.
2. Using a new O-ring seal (2), install the fuel drain/water in fuel sensor assembly (3) and securely tighten.
3. Connect the water in fuel sensor wire harness connector.
5. Connect both negative battery cables.
6. Prime the fuel system. Refer to FUEL SYSTEM PRIMING - DIESEL .

Fig. 251: EVIC Switches

8. Once the fuel filter maintenance has been performed, the Fuel Filter Life monitor can be reset by:
Vehicle in RUN with engine OFF (no RPM)
Hold the right arrow (3) down to reset the monitor.
FITTING, QUICK CONNECT
DESCRIPTION
DESCRIPTION
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. Refer to FITTING, QUICK CONNECT .

breakage.
STANDARD PROCEDURE
STANDARD PROCEDURE

DISCONNECTING
WARNING: On vehicles equipped with gasoline engines, 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.

breakage.
REDUNDANT LATCH SINGLE BUTTON TYPE FITTING:
Fig. 252: Redundant Latch & Push Button

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. 253: Redundant Latch & Internal Latches

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
Fig. 254: Single Button Quick-Connect Fitting


1 - QUICK-CONNECT FITTING
2 - SINGLE PUSH-BUTTON
1. This type of fitting is equipped with a single push-button (2) located on the quick-connect fitting.
Fig. 255: Fitting Latches

1 - LATCHES
2. The push-button is attached to two internal latches (1). To disconnect, press on push-button with your
thumb and unlatch fitting from fuel line. Tools are not required for disconnection. DO NOT ATTEMPT
TO PRY OR PULL UP ON PUSH BUTTON. LATCHES WILL BE BROKEN.
TWO BUTTON TYPE FITTING

Fig. 256: 2-Button Type Fitting

2 - PUSH-BUTTONS (2)
1. This type of fitting (1) is equipped with a push-button located on each side of quick-connect fitting (2).
Press on both buttons simultaneously for removal. Tools are not required for disconnection.
2. Press on both push buttons with your thumb, release the internal latches.
3. While holding the two push buttons simultaneously, remove the quick-connect fitting from the fuel
system component.
PINCH TYPE FITTING

Fig. 257: Pinch Type Quick-Connect Fitting

1 - QUICK-CONNECT FITTINGS
2 - PINCH TABS
1. This fitting (1) is equipped with two finger tabs (2). Pinch both tabs together while removing fitting.
Tools are not required for disconnection.
SINGLE TAB TYPE FITTING
Fig. 258: Single-Tab Type Fitting


1 - PULL TAB
3 - PRESS HERE TO REMOVE PULL TAB
4 - INSERTED TUBE END
1. This type of fitting (2) is equipped with a single pull tab (1). The tab is removable. After tab is removed,
quick-connect fitting can be separated from fuel system component. Tools are not required for
disconnection.
Fig. 259: Disconnecting Single-Tab Type Fitting

1 - PULL TAB
2 - SCREWDRIVER
2. 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.
3. While pressing release tab on side of fitting, use screwdriver (2) to pry up pull tab.
4. Raise pull tab until it separates from quick-connect fitting.
TWO TAB TYPE FITTING

Fig. 260: Typical Two-Tab Type Quick-Connect Fitting

1 - TAB(S)
1. This type of fitting (2) is equipped with tabs located on both sides of fitting (1). The tabs are supplied for
disconnecting quick-connect fitting from component being serviced.
a. To disconnect quick-connect fitting, squeeze plastic retainer tabs (1) against sides of quick-connect
fitting with your fingers. Tool use is not required for removal and may damage plastic retainer.
b. Pull fitting from fuel system component being serviced.
c. The plastic retainer will remain on component being serviced after fitting is disconnected. The O-
rings and spacer will remain in quick-connect fitting connector body.
PLASTIC RETAINER RING TYPE FITTING

Fig. 261: Plastic Retainer Ring Type Fitting

1 - FUEL TUBE
2 - QUICK CONNECT FITTING
3 - PUSH
4 - PLASTIC RETAINER
5 - PUSH
6 - PUSH
7 - PUSH
8 - PUSH
1. This type of fitting can be identified by the use of a full-round plastic retainer ring (4) usually black in
color.
a. To release fuel system component from quick-connect fitting, firmly push fitting towards
component being serviced while firmly pushing plastic retainer ring into fitting (6). With plastic
ring depressed, pull fitting from component. The plastic retainer ring must be pressed squarely
into fitting body. If this retainer is cocked during removal, it may be difficult to disconnect
fitting. Use an open-end wrench on shoulder of plastic retainer ring to aid in disconnection.
b. After disconnection, plastic retainer ring will remain with quick-connect fitting connector body.
c. Inspect fitting connector body, plastic retainer ring and fuel system component for damage.
Replace as necessary.
LATCH CLIPS - TYPE 1

Fig. 262: Latch Clip-Type 1

1 - TETHER STRAP
2 - FUEL LINE
3 - SCREWDRIVER
4 - LATCH CLIP
5 - FUEL RAIL
1. Depending on vehicle model and engine, three different types of safety latch clips are used. Types 1 and 3
(4) are tethered to fuel line and type 2 is not. A special tool will be necessary to disconnect fuel line after
latch clip is removed. The latch clip may be used on certain fuel line/fuel rail connection, or to join fuel
lines together.
2. Pry up on latch clip with a screwdriver (3).
3. Slide latch clip toward fuel rail while lifting with screwdriver.


1 - SPECIAL FUEL LINE TOOL

2 - FUEL LINE
3 - FUEL RAIL
4. Insert the appropriate fuel line removal tool (1) into the quick-connect fitting and release the internal
latches.
NOTE: After disconnection, locking fingers will remain within quick-connect

fitting at end of fuel line.
5. With the special tool still inserted, remove quick-connect fitting from fuel system component being
serviced.

Fig. 264: Latch Clip - Type 2

1 - LATCH CLIP
1. Depending on vehicle model and engine, 2 different types of safety latch clips are used. Type 1 is tethered
to fuel line and type 2 is not. A special tool will be necessary to disconnect fuel line after latch clip is
removed. The latch clip may be used on certain fuel line/fuel rail connection, or to join fuel lines together.
2. Type 2: Separate and unlatch 2 small arms (1) on end of clip and swing away from fuel line.
3. Slide latch clip toward fuel rail while lifting with screwdriver.

1 - SPECIAL FUEL LINE TOOL

2 - FUEL LINE
3 - FUEL RAIL
4. Insert the appropriate fuel line removal tool (1) into the quick-connect fitting and release the internal
latches.
NOTE: After disconnection, locking fingers will remain within quick-connect

fitting at end of fuel line.
5. With the special tool still inserted, remove quick-connect fitting from fuel system component being
serviced.
Fig. 266: Latch Clips - Type 3

1. A special tool is not necessary to disconnect fuel line after latch clip is removed. The latch clip is used to
join fuel lines together.
2. Type 3: Separate and unlatch 2 small arms on the end of clip and swing away from the fuel line.
CONNECTING
1. Inspect quick-connect fitting body and fuel system component for damage. Replace as necessary.

2. Prior to connecting quick-connect fitting to component being serviced, check condition of fitting and
component. Clean parts with a lint-free cloth. Lubricate with clean engine oil.
3. Insert quick-connect fitting into fuel tube or fuel system component until built-on stop on fuel tube or
component rests against back of fitting.
4. Continue pushing until a click is felt.
5. Redundant Latch Single Button Type Fitting: Push redundant latch until it locks into position in the
quick-connect fitting.
6. Single-tab type fitting: Push new tab down until it locks into place in quick-connect fitting.
7. Latch Clip Equipped: Install latch clip (snaps into position). If latch clip will not fit, this indicates fuel
line is not properly installed to fuel rail (or other fuel line). Recheck fuel line connection.
8. Verify a locked condition by firmly pulling on the quick-connect fitting connection of the fuel system
component.
HEATER, FUEL
DESCRIPTION
DESCRIPTION
The Fuel Heater 1 is located in the fuel filter/water separator housing assembly and is located on the engine.
The Fuel Heater 2 is located in the fuel filter/water separator housing assembly and is located on the frame rail.
The fuel heater is not a serviceable component. If diagnosis has lead you to replace the fuel heater then the
whole fuel filter/water separator housing must be replaced.
OPERATION
OPERATION - FUEL HEATER 1
The fuel heater is used to prevent diesel fuel from waxing during cold weather operation.
When the fuel temperature is below 32° F (0° C), the temperature sensor allows current to flow to the heater
element warming the fuel. When the fuel temperature is above 64° F (18° C), the sensor stops current flow to
the heater element.
Battery voltage to operate the fuel heater element is supplied from the ignition switch and through a relay the
PDC. The fuel heater element and "relay in PDC" are not computer controlled. The heater element
operates on 12 volts, 300 watts at 0° F (-18° C).
OPERATION - FUEL HEATER 2
When the fuel temperature is below 32° F (0° C), the temperature sensor allows current to flow to the heater
element warming the fuel. When the fuel temperature is above 64° F (18° C), the sensor stops current flow to
the heater element.

Battery voltage to operate the fuel heater element is supplied from the ignition switch and through a relay the
PDC. The fuel heater element and "relay in PDC" are not computer controlled. The heater element
operates on 12 volts, 300 watts at 0° F (-18° C).
DIAGNOSIS AND TESTING - FUEL HEATER - 1
NOTE: The fuel heater element, "relay in the PDC" is not controlled by the Powertrain
Control Module (PCM).
A malfunctioning fuel heater can cause a wax build-up in the fuel filter/water separator. Wax build-up in the
filter/separator can cause engine starting problems and prevent the engine from revving up. It can also cause
blue or white fog-like exhaust. If the heater is not operating in cold temperatures, the engine may not operate
due to fuel waxing.
The fuel heater assembly is located on the side of fuel filter housing and internal to the fuel filter housing.
The heater assembly is equipped with a built-in fuel temperature sensor (thermostat) that senses fuel
temperature. When fuel temperature drops below 32° F (0° C), the sensor allows current to flow to built-in
heater element to warm fuel. When fuel temperature rises above 64° F (18° C), the sensor stops current flow to
heater element (circuit is open).
Voltage to operate fuel heater element is supplied from ignition switch, through "relay in the PDC", to fuel
temperature sensor and on to fuel heater element.
The heater element operates on 12 volts, 300 watts at 0 °F (-18° C). As temperature increases, power
requirements decrease.
A minimum of 7 volts is required to operate the fuel heater. The resistance value of the heater element is less
than 1 ohm (cold) and up to 1000 ohms warm.
TESTING

Fig. 267: Fuel Filter Housing Assembly & Harness Connector

NOTE: The Fuel Heater is not a separately serviceable component. If diagnostics have
led you to replace this sensor, then the whole fuel filter housing assembly (3)
needs to be changed.
1. Disconnect harness connector (1) from heater element.
Ambient temperature must be below the circuit close temperature. If necessary, induce this ambient
temperature by placing ice packs on thermostat to produce an effective ambient temperature below circuit
close temperature.
Measure resistance across two pins. Operating range is 0.3 - 0.45 Ohms.
2. If resistance is out of range, replace the fuel filter housing.
DIAGNOSIS AND TESTING - FUEL HEATER - 2
NOTE: The fuel heater element, "relay in the PDC" is not controlled by the Powertrain
Control Module (PCM).
A malfunctioning fuel heater can cause a wax build-up in the fuel filter/water separator. Wax build-up in the
filter/separator can cause engine starting problems and prevent the engine from revving up. It can also cause
blue or white fog-like exhaust. If the heater is not operating in cold temperatures, the engine may not operate
due to fuel waxing.
The fuel heater assembly is located on the side of fuel filter housing and internal to the fuel filter housing.

The heater assembly is equipped with a built-in fuel temperature sensor (thermostat) that senses fuel
temperature. When fuel temperature drops below 32° F (0° C), the sensor allows current to flow to built-in
heater element to warm fuel. When fuel temperature rises above 64° F (18° C), the sensor stops current flow to
heater element (circuit is open).
Voltage to operate fuel heater element is supplied from ignition switch, through "relay in the PDC", to fuel
temperature sensor and on to fuel heater element.
The heater element operates on 12 volts, 300 watts at 0 °F (-18° C). As temperature increases, power
requirements decrease.
A minimum of 7 volts is required to operate the fuel heater. The resistance value of the heater element is less
than 1 ohm (cold) and up to 1000 ohms warm.
TESTING - 2
Fig. 268: Negative Battery Cables

led you to replace this sensor, then the whole fuel filter housing assembly
needs to be changed.
1. Disconnect harness connector (2) from heater element.
NOTE: Ambient temperature must be below the circuit close temperature. If

necessary, induce this ambient temperature by placing ice packs on

thermostat to produce an effective ambient temperature below circuit

close temperature.
2. Measure resistance across two pins. Operating range is 0.3 - 0.45 Ohms.
3. If resistance is out of range, replace the fuel filter housing.
REMOVAL
REMOVAL
led you to replace this sensor, then the whole fuel filter housing assembly
needs to be changed. Refer to SEPARATOR AND FILTER, FUEL AND WATER,
REMOVAL.
MANIFOLD, FUEL DRAIN
OPERATION
OPERATION
The Fuel Drain Circuit incorporates several sources of fuel return. Fuel travels from the fuel tank (via the fuel
transfer pump) and is forced through the fuel filter. This fuel then travels into the fuel injection pump. It then
goes to a fuel drain line and returns back to the fuel tank.
The fuel that flows to the fuel pump is pressurized by a gear pump and internally transferred to the fuel injection
pump. At this point the fuel is channeled into two passages. One passage sends fuel to the FCA (Fuel Control
Actuator). The other passage sends fuel to the cascade overflow valve. The overflow valve sends some fuel to a
lubrication passage. The rest of the fuel is sent to a drain passage which connects to an external fuel line.
Fuel that travels through the FCA is pressurized by the fuel injection pump and sent through an external high
pressure fuel line to the fuel rail. At the fuel rail, fuel is sent to the fuel injectors. If fuel pressure in the fuel rail
becomes excessive, the pressure limiting valve opens and sends fuel through an external fuel line.
At the fuel injector, fuel that is not injected is used for lubrication of the fuel injectors. This fuel then travels
through an internal passage that is connected to the rear of the cylinder head, an then into an external fuel line.
This line is connected to the vehicles fuel return line, and returns excess fuel back and into the fuel tank.
REMOVAL
REMOVAL

Housing
one quarter turn counter clockwise to open it. Turn the key to the "ON" position. This will cycle the fuel
pump for 2 seconds and drain the fluid from the fuel filter housing. Turn the key to the "OFF" position
and rotate the drain valve (4) clockwise one quarter turn to close it.
2. Disconnect drain hose (6) from the fuel drain valve.
3. Remove four drain valve mounting screws (5) and the drain valve (4) from filter housing (1).
INSTALLATION
INSTALLATION

Housing
TRANSFER .
1. Install the drain valve (4) to filter housing (1) and securely tighten the four drain valve mounting screws.
2. Connect drain hose (6) from the fuel drain valve.
MODULE, FUEL PUMP
DESCRIPTION
DESCRIPTION
The fuel tank module is installed in the top of the fuel tank. The fuel tank module contains the following
components:
An electric fuel transfer (lift) pump

Fuel reservoir
A separate in-tank fuel filter
Fuel gauge sending unit (fuel level sensor)
Fuel supply line connection
A special lockring to retain module to fuel tank

Fuel return line connection
REMOVAL
REMOVAL
Fig. 271: Using Fuel Pump Lock Ring Wrench 9340 To Remove or Install Fuel Pump Module
1. Drain the fuel tank. Refer to DRAINING FUEL TANK .

2. Remove fuel tank. Refer to TANK, FUEL, REMOVAL.
3. Note rotational position of module before attempting removal. An indexing arrow is located on top of
module for this purpose.
4. Position SAE Fuel Pump Lock Ring Wrench (special tool #9340, SAE Fuel Pump Lock Ring Wrench)
(3) into notches on outside edge of lock ring (5).
5. Install 1/2 inch drive breaker bar (1) to SAE Fuel Pump Lock Ring Wrench (special tool #9340, SAE
Fuel Pump Lock Ring Wrench) (3).
6. Rotate breaker bar counterclockwise to remove lock ring.
7. Remove lock ring. The module will spring up slightly when lock ring is removed.
8. Remove module from fuel tank. Be careful not to bend float arm while removing.
INSTALLATION
INSTALLATION

Fig. 272: Aligning Locator Tab With Index Mark

CAUTION: Whenever the fuel pump module is serviced, the rubber O-ring seal must
be replaced.
1. Using a new O-ring seal (gasket), position fuel pump module into opening in fuel tank and align the
locator tab (A) with index mark (A) on fuel tank.
Fig. 273: Using Fuel Pump Lock Ring Wrench 9340 To Remove or Install Fuel Pump Module
2. Position lock ring (5) over top of fuel pump module.

3. Rotate module until embossed alignment arrow points to center alignment mark. This step must be

performed to prevent float from contacting side of fuel tank. Also be sure fuel fitting on top of pump
module is pointed to drivers side of vehicle.
4. Install SAE Fuel Pump Lock Ring Wrench (special tool #9340, SAE Fuel Pump Lock Ring Wrench) (3)
to lock ring.
5. Install 1/2 inch drive breaker (1) into SAE Fuel Pump Lock Ring Wrench (special tool #9340, SAE Fuel
6. Tighten lock ring (clockwise) until all seven notches have engaged.
7. Install fuel tank. Refer to TANK, FUEL, INSTALLATION.
PUMP, FUEL INJECTION
DESCRIPTION
DESCRIPTION
A Robert Bosch high-pressure fuel injection pump is used. The pump is attached to the back of the timing gear
housing at the left/front side of the engine.
OPERATION
OPERATION
The fuel injection pump supplies high pressure to the fuel rail independent of engine speed. This high pressure
is then accumulated in the fuel rail. High pressure fuel is constantly supplied to the injectors by the fuel rail. The
Powertrain Control Module (PCM) controls the fueling and timing of the engine by actuating the injectors.
Fuel enters the system from the electric fuel transfer (lift) pump, which is located in the fuel tank. Fuel is forced
through the fuel filter element and then enters the Fuel Pump/Gear Pump, which is attached to the rear of the
fuel injection pump. The Fuel Pump/Gear Pump is a low-pressure pump and produce a minimum pressure of
440 kPa (64 psi). Fuel then enters the fuel injection pump. Low pressure fuel is then supplied to the Fuel
Control Actuator (FCA).
The FCA is an electronically controlled solenoid valve. The PCM controls the amount of fuel that enters the
high-pressure pumping chambers by opening and closing the FCA based on a demanded fuel pressure. The Fuel
Pressure Sensor (FPS) on the fuel rail provides the actual fuel pressure. When the actuator is opened, the
maximum amount of fuel is being supplied to the fuel injection pump. Any fuel that does not enter the injection
pump is directed to the cascade overflow valve. The cascade overflow valve regulates how much excess fuel is
used for lubrication of the pump and how much is returned to the tank through the drain manifold.
Fuel entering the injection pump is pressurized to between 200 -1800 bar (2901 - 26107 psi) by three radial
pumping chambers. The pressurized fuel is then supplied to the fuel rail.
REMOVAL
REMOVAL


Fig. 274: Engine Cover, Bolts & Oil Dipstick


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

Fig. 275: Bulk Head Connector

4. Cut the cable tie and position aside the bulk head connector (1).
Fig. 276: EGR Bypass Valve Harness Connector & Exhaust Pressure Sensor Wire Harness
Connector
5. Disconnect the exhaust pressure sensor wire harness connector (2).

6. Disconnect the EGR cooler bypass valve wire harness connector (1).

Fig. 277: Crankcase Pressure Sensor Wire Harness Connector & Clamp
7. Disconnect the crankcase pressure sensor 2 wire harness connector (1).
Fig. 278: Identifying Crankcase Pressure Sensor And Components

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

Fig. 279: Injector Harness Connectors

9. Disconnect both fuel injector wire harness connectors (1).
Fig. 280: CCV Tube, Crankcase Pressure Sensor Connector, CCV Oil Drains & Close Crankcase
Ventilation (CCV) Cover
10. Remove the CCV oil drains hoses (3) from cylinder head cover.
11. Remove the fuel tube silencer.

Fig. 281: Intake Manifold Air Intake Tube And Connecting Hose
12. Loosen clamps (4) and remove the Charge Air Cooler (CAC) tube (3) (above injection pump).
13. Remove the accessory drive belt. Refer to BELT, SERPENTINE, REMOVAL .
Fig. 282: Identifying Banjo Bolt And Fuel Control Actuator Electrical Connector

14. Thoroughly clean rear of injection pump, and attachment points for its fuel lines. Also clean the opposite
ends of these same lines at their attachment points.
15. Disconnect quick-connect fitting by pressing on button (1).
CAUTION: Whenever a fuel line fitting is connected to a secondary fitting,

always use a back-up wrench on the secondary fitting. Do not allow
the secondary fitting to rotate.
16. Remove banjo bolt (2).

17. Disconnect FCA (Fuel Control Actuator) wire harness connector (3).
Fig. 283: Fuel Injection Pump Components - Rear View

18. Remove line clamp (5).

Fig. 284: Fuel Rail Components

19. Remove the high pressure pump-to-fuel rail fuel tube (5).
Fig. 285: Pump Drive Gear Access Cover


20. Remove fuel pump drive gear access cover with a 3/8" drive ratchet. Access cover (2) is threaded to
timing gear cover.
21. Remove fuel pump drive gear mounting nut and washer.
Fig. 286: Removing Pump Drive Gear

22. Attach C3428B, or (special tool #L-4407A, Puller, Gear) (or equivalent) gear puller (1) to pump drive
gear with 2 bolts, and separate gear from pump (a keyway is not used on this particular injection pump).
Leave drive gear hanging loose within timing gear cover.

Fig. 287: Fuel Injection Pump & Mounting Components

23. Remove three injection pump mounting nuts (6), and remove pump from engine.
INSTALLATION
INSTALLATION



1. Inspect pump mounting surfaces at pump and mounting flange and pilot bore for nicks, cuts or damage.
Inspect O-ring surfaces for nicks, cuts or damage.
2. Clean injection pump mounting flange and pilot bore at gear housing. Also clean front of injection pump.
3. Install new rubber O-ring (square) (4) into machined groove at pump mounting area.
4. Apply clean engine oil to injection pump O-ring and pilot bore only.
The machined tapers on both injection pump shaft and injection pump gear must be absolutely dry,
clean and free of any dirt or oil film. This will ensure proper gear-to-shaft tightening.
5. Clean pump gear and pump shaft at machined tapers with an evaporative type cleaner such as brake
cleaner.

Fig. 289: Injection Pump Shaft Phasing Marks

6. FUEL INJECTION PUMP PHASING: Perform the following phasing procedure anytime the injection
pump has been removed and reinstalled.
7. Locate the end of the fuel injection pump shaft (2). Two numbers (750 or 754 and 0) are stamped into the
end of the shaft.
Fig. 290: Injection Pump Shaft Position


NOTE: Fuel Injection Pump used for illustration has number 750.
8. Rotate the injection pump shaft until the number 5 (located in the center of number 750 or 754) is
positioned at 9 o'clock (1).
9. Position injection pump to mounting flange on gear housing while aligning injection pump shaft through
back of injection pump gear. Be sure the number 5 is still at the 9 o'clock position (1).
10. Bring the engine to TDC position. Do this by rotating the crankshaft until the TDC mark on the
crankshaft damper is at 12 o'clock position. It does not matter if cylinder No. 1 or No. 6 is at TDC. Again,
check to be sure the number 5 is still at the 9 o'clock position (1). Rotate pump shaft accordingly.

11. After pump is positioned flat to mounting flange, install three pump mounting nuts (6) and tighten finger
tight only. Do not attempt a final tightening at this time. Do not attempt to tighten (pull) pump to gear
housing using mounting nuts. Damage to pump or gear housing may occur. The pump must be
positioned flat to its mounting flange before attempting to tighten three mounting nuts.
12. To prevent damage or cracking of components, install and tighten nuts in the following sequence:
a. Install fuel injection pump shaft washer and nut to pump shaft. Tighten nut finger tight only.
b. Do preliminary (light) tightening of fuel injection pump shaft nut (1).
c. Tighten three fuel injection pump mounting nuts to 24 N.m (18 ft. lbs.).
d. Do a final tightening of fuel injection pump shaft nut (1) to 105 N.m (77 ft. lbs.).

Fig. 292: Pump Drive Gear Access Cover

13. Install drive gear access cover (2) using a 3/8" drive ratchet. Access cover is threaded to timing gear
cover. Tighten to 8 N.m (71 in. lbs.).


14. Install the high-pressure pump-to-fuel rail fuel tube (5) and tighten union nuts to 40 N.m (30 ft. lbs.).

15. Install fuel return line. Tighten banjo bolt (2) to 24 N.m (18 ft. lbs.).
16. Install quick-connect fitting (4).
17. Install clamp (5).
18. Connect Fuel Control Actuator (FCA) wire harness connector (6) to rear of injection pump.

Fig. 295: Intake Tube & Connecting Hose

19. Install accessory drive belt. Refer to BELT, SERPENTINE, INSTALLATION .

20. Install the Charge Air Cooler (CAC) tube (3) Tighten clamps (4) to 14 N.m (124 in. lbs.).
Fig. 296: CCV Tube, Crankcase Pressure Sensor Connector, CCV Oil Drains & Close Crankcase
Ventilation (CCV) Cover

22. Install the CCV oil drains hoses (3) to the cylinder head cover.

23. Disconnect both fuel injector wire harness connectors (1).

24. Connect the crankcase pressure sensor 1 wire harness connectors (7).

25. Connect the crankcase pressure sensor 2 wire harness connector (1).
Connector
26. Connect the EGR cooler bypass valve wire harness connector (1).
27. Connect the exhaust pressure sensor wire harness connector (2).


28. Position the bulk head connector (1) and install a new cable tie to secure connector.

29. Install the engine cover (3). Tighten bolts (1) to 10 N.m (89 in. lbs.).
30. Install the oil dipstick (2).
32. Check system for fuel or engine oil leaks.

PUMP, FUEL TRANSFER
DESCRIPTION
DESCRIPTION
The fuel transfer pump (fuel lift pump) is part of the fuel pump module. The fuel pump module is located in the
fuel tank. The 12-volt electric pump is operated and controlled by the Powertrain Control Module (PCM). The
PCM controls a relay in the Intelligent Power Module (IPM) for transfer pump operation.
OPERATION
OPERATION
The purpose of the fuel transfer pump is to supply (transfer) a low-pressure fuel source: from the fuel tank,
through the fuel filter/water separator and to the fuel injection pump. Here, the low-pressure is raised to a high-
pressure by the fuel injection pump for operation of the high-pressure fuel injectors. Check valves within the
pump, control direction of fuel flow and prevent fuel bleed-back during engine shut down.
Maximum current flow to the pump is 5 amperes.
With the engine running, the pump has a 100 percent duty-cycle.
The transfer pump is self-priming: When the key is first turned on (without cranking engine), the pump will
operate for approximately 2 seconds and then shut off (Note: When ambient temperatures are cold enough to
cause the intake air heaters to operate, the fuel lift pump will operate during the entire intake air pre-heat cycle).
The pump will also operate for up to 25 seconds after the starter is engaged, and then disengaged and the engine
is not running. The pump shuts off immediately if the key is on and the engine stops running.
The fuel volume of the transfer pump will always provide more fuel than the fuel injection pump requires.
Excess fuel is returned from the injection pump through an overflow valve, and then back to the fuel tank.
REMOVAL
REMOVAL
The fuel transfer pump (fuel lift pump) is a part of the fuel tank module. It is not serviced separately. Refer to
Fuel Tank Module Removal or Installation for procedures. Refer to MODULE, FUEL PUMP, REMOVAL.
INSTALLATION
INSTALLATION
The fuel transfer pump (fuel lift pump) is a part of the fuel tank module. It is not serviced separately. Refer to
MODULE, FUEL PUMP, INSTALLATION.
RAIL, FUEL

OPERATION
OPERATION
The fuel rail is used as a distribution device to supply high-pressure fuel to the high-pressure fuel injectors.
REMOVAL
REMOVAL


1. Disconnect both negative battery cables.



Connector



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


9. Disconnect both fuel injector harness connectors (1).
Fig. 309: Oil Drain Hose

10. Remove the CCV oil drains hose (2) from cylinder head cover.

Fig. 310: Fuel Tube Silencer

Fig. 311: Fuel Pressure Sensor & Harness Connector

12. Disconnect the fuel pressure sensor harness connector (2).


CAUTION: WHEN LOOSENING OR TIGHTENING HIGH-PRESSURE LINE

FITTINGS (11) ATTACHED TO A SEPARATE FITTING (12), USE A
BACK-UP WRENCH ON FITTING (12). DO NOT ALLOW FITTING (12)
TO ROTATE. DAMAGE TO BOTH FUEL LINE AND FITTING WILL
RESULT.
13. Remove the fuel tubes. Refer to TUBE(S), FUEL, REMOVAL.

14. Remove bolts (12) and the fuel rail (11).
INSTALLATION
INSTALLATION


1. Clean any dirt/debris from top of intake manifold and bottom of fuel rail.
2. Install fuel rail (11). Tighten bolts (12) to 24 N.m (18 ft. lbs.).

RESULT.
3. Install the fuel tubes. Refer to TUBE(S), FUEL, INSTALLATION.


4. Connect the fuel pressure sensor harness connector (2).

5. Install the fuel tube silencer.


6. Install the CCV oil drains hoses (2) to cylinder head cover.

7. Connect both fuel injector harness connectors (1).



Connector

12. Position the bulk head connector (1) and install a new cable tie to secure.

15. Start engine and check for leaks.

REMOVAL
REMOVAL
For diesel removal and installation procedures, refer to FUEL DELIVERY, GAS . See SENDING UNIT
AND SENSOR, FUEL LEVEL Removal/Installation.
SENSOR, FUEL PRESSURE
OPERATION
OPERATION
The fuel pressure sensor monitors actual high-pressure within the fuel rail. An output signal from this sensor
(relating to fuel pressure) is sent to the Powertrain Control Module (PCM).
REMOVAL
REMOVAL




5. If equipped, remove the transmission dipstick (3).

Connector








12. Remove the fuel tube silencer (1).
Fig. 331: Removing/Installing Fuel Line Shield, High Pressure Fuel Lines, HPC Connector Tube,
Fuel Injectors & Bolts
13. Remove two bolts (4) and No. 6 fuel tube shield (5) at rear of cylinder head.
14. Remove cylinder No. 5 and No. 6 fuel lines (3 and 6).

15. Disconnect the fuel pressure sensor wire harness connector (2).

Fig. 333: Remove/Install Fuel Pressure Sensor

NOTE: Do not use an impact socket, the socket wall is too thick and will not work.
16. Using a 27 mm thin walled socket (3), remove fuel pressure sensor (2).
INSTALLATION
INSTALLATION
Fig. 334: Remove/Install Fuel Pressure Sensor


1. Inspect fuel pressure sensor sealing surface on fuel rail (1).

2. Lubricate sensor threads with clean diesel fuel.
CAUTION: Only use a socket when installing the fuel pressure sensor. Failure to
follow these instructions will damage the fuel pressure sensor.
NOTE: Do not use an impact socket, the socket wall is too thick and will not work.
3. Using a 27 mm thin walled socket (3), install fuel pressure sensor (2). Tighten sensor to 70 N.m (52 ft.
lbs.).

4. Connect fuel pressure sensor wire harness connector (2).

CAUTION: Anytime a high-pressure line is removed from the engine, its fuel
connector nut (12) at the cylinder head must first be retorqued.
5. Tighten the fuel injector connector retainer nut (13) at the cylinder head to 55 N.m (41 in. lbs.).
6. Install cylinder No. 5 and No. 6 fuel tubes (3 and 6).
7. Tighten fuel tube at cylinder head to 40 N.m (30 ft. lbs.).
8. Tighten fuel tube nuts at fuel rail to 40 N.m (30 ft. lbs.).
9. Install the No. 6 fuel tube shield (5). Tighten bolts (4) to 43 N.m (32 ft. lbs.).


10. Install the fuel tube silencer (1).





Connector


20. Start engine and check for fuel leaks.


SENSOR, WATER IN FUEL
DESCRIPTION
DESCRIPTION
For 2013 model year there are two Water-In-Fuel (WIF) sensor being used. The primary one is located on the
engine, and the secondary one is located on the frame rail near the fuel tank.
Housing
The primary WIF sensor (3) is located on the bottom of the fuel filter/water separator housing (1).


The secondary WIF sensor (3) is located on the bottom of the fuel filter (1).
OPERATION
OPERATION
The sensor sends an input to the Powertrain Control Module (PCM) when it senses water in the fuel filter/water
separator. As the water level in the filter/separator increases, the resistance across the Water in Fuel (WIF)
sensor decreases. This decrease in resistance is sent as a signal to the PCM and compared to a high water
standard value. Once the value reaches 30 to 40 kilohms, the PCM will activate the water-in-fuel warning lamp
through CCD bus circuits. This all takes place when the ignition key is initially put in the ON position. The
PCM continues to monitor the input while the engine is running.
REMOVAL
PRIMARY

Housing
one quarter turn counter clockwise to open it. Also, loosen the fuel filter housing cover a 1/2 turn and
allow the fuel drain from the fuel filter housing for two minutes. Rotate the drain valve (4) clockwise one
quarter turn to close it.
2. Disconnect the Water In Fuel (WIF) sensor harness connector (2).
3. Remove the WIF sensor (3).
SECONDARY



2. Position a drain pan under fuel filter and open fuel drain valve and drain fuel.
3. Disconnect the Water In Fuel (WIF) sensor harness connector.
4. Remove the WIF sensor (3).
INSTALLATION
PRIMARY

Housing
NOTE: The engine has a self-priming low-pressure fuel system. To prim the fuel
system. Refer to PUMP, FUEL TRANSFER .
1. Using a new O-ring, install the Water in Fuel (WIF) sensor (3) and securely tighten the WIF sensor.
2. Connect the WIF sensor harness connector (2).
SECONDARY


1. Using a new O-ring (2), install the Water in Fuel (WIF) sensor (3) and securely tighten.
2. Connect the WIF sensor harness connector.
4. The engine has a self-priming low-pressure fuel system. To prim the fuel system. Refer to PUMP, FUEL
TRANSFER .
SEPARATOR AND FILTER, FUEL AND WATER
DESCRIPTION
DESCRIPTION
The fuel filter/water separator 1 is located on left side of engine above the starter motor. The fuel filter/water
separator 2 is located on frame rail by the fuel tank. The assembly also includes the fuel heater, water drain
valve, Water-In-Fuel (WIF) sensor.
OPERATION
OPERATION
The fuel filter/water separator protects the fuel injection pump by removing water and contaminants from the
fuel. The construction of the filter/separator allows fuel to pass through it, but helps prevent moisture (water)
from doing so. Moisture collects at the bottom of the filter.

Refer to the maintenance schedules in the Owner's Manual for the recommended fuel filter replacement
intervals.
For draining of water from canister, refer to Fuel Filter/Water Separator REMOVAL and INSTALLATION .
A Water-In-Fuel (WIF) sensor is attached to the bottom of fuel filter element. Refer to Water-In-Fuel Sensor
DESCRIPTION and OPERATION .
The fuel heater is installed into the side of the filter/separator housing. Refer to Fuel Heater DESCRIPTION
and OPERATION .
REMOVAL
FUEL FILTER-WATER SEPARATOR 1


2. Remove the oil dip stick (2).

Fig. 352: Identifying Drain Valve, Drain Hose, Mounting Screws, Sensor Harness Connector &
Filter Housing
4. Remove all low-pressure fuel lines at filter housing.

5. Disconnect the Water In Fuel (WIF) sensor harness connector (2).

6. Disconnect the fuel heater harness connector (1).

Fig. 354: Fuel Filter Housing Components

7. Remove bolts (4) and the fuel filter housing (3).
Fig. 355: Fuel Tube Components

8. If required, remove fitting (4) and the sealing washers (5).

9. If required, remove banjo bolt (7), sealing washers (6), and the fuel tube (8).

10. If required, remove banjo bolt (14) and the sealing washers (13).
11. If required, remove banjo bolt (11), sealing washers (10), the fuel return tube (12).

12. If required, remove bolts (2 and 5) and the fuel filter housing bracket (1).


1. Disconnect and isolate both negative battery cable.

3. Disconnect the fuel heater wire harness connector (2) and detach wire retainer (1).

Fig. 358: WIF Sensor Components

4. Disconnect the Water In Fuel (WIF) sensor wire harness connector (1) and detach wire harness retainer
(2).
5. Remove the low-pressure fuel lines (3, 4) at filter housing.
Fig. 359: Fuel Filter Housing & Nuts

6. Remove nuts (1) and the fuel filter housing (2) from frame.
INSTALLATION
TRANSFER .


1. If required, Install the fuel filter housing bracket (1). Tighten bolts (2 and 5) to 24 N.m (18 ft. lbs.).
Fig. 361: Fuel Tube Components

2. If required, using new sealing washers (10) install the fuel return tube (12). Tighten banjo bolt (11) to 24

N.m (18 ft. lbs.).

3. If required, using new sealing washers (13) tighten banjo bolt (14) at the back of cylinder head to 24 N.m
(18 ft. lbs.).
4. If required, using new sealing washers (6) install the fuel tube (8) to fuel rail. Tighten banjo bolt (7) to 24
N.m (18 ft. lbs.).
5. If required, using new sealing washers (5) tighten fitting (4) at fuel filter housing to 24 N.m (18 ft. lbs.).

6. Install fuel filter housing (3). Tighten bolts (4) to 24 N.m (18 ft. lbs.).


7. Connect the fuel heater harness connector (1).
Fig. 364: Identifying Drain Valve, Drain Hose, Mounting Screws, Sensor Harness Connector &
Filter Housing
8. Connect the Water In Fuel (WIF) sensor harness connector (2).

9. Install all low-pressure fuel lines at filter housing.


11. Install the oil dip stick (2).
TRANSFER .

Fig. 366: Fuel Filter Housing & Nuts

1. Install fuel filter housing (2) to frame. Tighten nuts (1) to 32 N.m (24 ft. lbs.).
Fig. 367: WIF Sensor Components


2. Install all low-pressure fuel lines (3, 4) at filter housing.

3. Attach wire harness retainer (1) and connect the Water In Fuel (WIF) sensor wire harness connector (2).

4. Attach wire harness retainer (1) and connect the fuel heater wire harness connector (2).
6. Connect both negative battery cable.
TANK, FUEL
REMOVAL
REMOVAL

Fig. 369: Fuel Tank Fill/Vent Hoses - Mid Tank


2. Raise and support vehicle. Refer to HOISTING, STANDARD PROCEDURE .
3. Drain the fuel tank. Refer to DRAINING FUEL TANK .
4. Loosen hose clamps (3).
5. Remove hoses (4) and (6) from tank.

Fig. 370: Electrical Connector - Mid Tank

6. Disconnect fuel pump module wire harness connector (1).
Fig. 371: Fuel Line Connections - Diesel Mid Tank

7. Disconnect the fuel return and supply line quick-connect fittings (4) and (5). Refer to FITTING, QUICK
CONNECT .

8. Position a transmission jack under fuel tank.
Fig. 372: Fuel Tank Mounting - Mid Tank

9. Remove nuts (5) and both fuel tank straps (4).

10. Lower the transmission jack and remove fuel tank.
11. If necessary, remove the fuel pump module. Refer to MODULE, FUEL PUMP, REMOVAL.
INSTALLATION
INSTALLATION

Fig. 373: Fuel Tank Mounting - Mid Tank

1. If removed, install the fuel pump module. Refer to MODULE, FUEL PUMP, INSTALLATION.
2. Position the fuel tank assembly onto a transmission jack.
3. Raise fuel tank assembly up to frame.
4. Install fuel tank straps (4). Tighten nuts (5) to 61 N.m (45 ft. lbs.).
5. Remove the transmission jack.

Fig. 374: Fuel Line Connections - Diesel Mid Tank

6. Connect fuel return and supply line quick-connect fittings (4 and 5).
Fig. 375: Electrical Connector - Mid Tank

7. Connect the fuel sending unit wire harness connector (1).

Connect the fuel vapor hose (2) to tank Fitting (1).
Fig. 376: Tank Fitting & Fuel Vapor Hose

8. Connect the fuel vapor hose (2) to tank fitting (1).
Fig. 377: Fuel Tank Fill/Vent Hoses - Mid Tank

9. Install the vent hoses (4) to tank fitting and securely tighten clamp (3).
10. Install the filler hoses (6) to tank fitting and securely tighten clamp.
13. Fill tank and check for leaks.
TUBE, FUEL TANK FILLER
REMOVAL
REMOVAL
Fig. 378: Fuel Tank Filler Tube

1. Disconnect and isolate the negative battery cable.

3. Disconnect the DEF filler hose at filler neck tube (2).
4. Disconnect the DEF vent hose at filler neck tube (1).
5. Partially lower the vehicle.
6. Remove the left rear wheel house splash shield. Refer to SHIELD, SPLASH, REAR WHEELHOUSE,
REMOVAL .

Fig. 379: Remove/Install Tubes

7. Loosen clamp (4) and disconnect the diesel fuel filler tube.
8. Loosen clamp (1) and disconnect the diesel fuel vent tube (2).
9. Remove nut (5) securing the ground wire (5) to frame rail.


10. Disconnect the fuel vapor hose (2) from tank fitting (1).
Fig. 381: DEF Cap


12. Remove the DEF cap (1).
Fig. 382: Fuel Filler Tube Screws

13. Remove screws and the fuel filler tube through wheel well.
INSTALLATION
INSTALLATION
Fig. 383: Fuel Filler Tube Screws

1. Install the fuel filler tube and securely tighten screws.

Fig. 384: DEF Cap

2. Install the DEF cap.

3. Connect the fuel vapor hose (2) to tank fitting (1).

Fig. 386: Remove/Install Tubes

4. Install the ground wire (5) to frame rail and securely tighten nut (6).
5. Connect the diesel fuel vent tube (2). Tighten the hose clamp (1) to 3 N.m (30 in. lbs.).
6. Connect the diesel fuel fill tube (3). Tighten the hose clamp (4) to 3 N.m (30 in. lbs.).
7. Install the left rear wheelhouse splash shield. Refer to SHIELD, SPLASH, REAR WHEELHOUSE,
INSTALLATION .
8. Raise the vehicle.

Fig. 387: Fuel Tank Filler Tube

9. Connect the DEF vent hose to filler neck tube (1).

10. Connect the DEF filler hose to filler neck tube (2).
12. Connect the negative battery cable.
13. Start the vehicle and check for leaks.
TUBE(S), FUEL
DESCRIPTION
DESCRIPTION
LOW-PRESSURE LINES ARE:
the fuel supply line from fuel tank to fuel filter housing.
the fuel return line back to fuel tank.
the fuel drain (manifold) line at rear of cylinder head.
the fuel supply line from fuel filter to fuel injection pump.
the fuel injection pump return line.
HIGH-PRESSURE LINES ARE:
the fuel line from fuel injection pump to fuel rail.

the six fuel lines from fuel rail up to injector connector tubes
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 180, 000
kPa (26, 107 psi). Use extreme caution when inspecting for high-pressure
fuel leaks. Inspect for high-pressure fuel leaks with a sheet of cardboard.
High fuel injection pressure can cause personal injury if contact is made
with the skin.
OPERATION
OPERATION
HIGH-PRESSURE LINES
CAUTION: The high-pressure fuel lines must be held securely in the brace. The lines
cannot contact each other or other components. Do not attempt to weld
high-pressure fuel lines or to repair lines that are damaged. If lines are
ever kinked or bent, they must be replaced. Use only the recommended
lines when replacement of high-pressure fuel line is necessary.
CAUTION: Do not squeeze low pressure fuel lines with pliers, vice grips, or similar
tools as this will damage to the fuel line.
High-pressure fuel lines deliver fuel (under pressure) of up to approximately 180, 000 kPa (26, 107 PSI) from
the injection pump to the fuel injectors. The lines expand and contract from the high-pressure fuel pulses
generated during the injection process. All high-pressure fuel lines are of the same length and inside diameter.
Correct high-pressure fuel line usage and installation is critical to smooth engine operation.
WARNING: Use extreme caution when inspecting for high-pressure fuel leaks.
Inspect for high-pressure fuel leaks with a sheet of cardboard. High fuel
injection pressure can cause personal injury if contact is made with the
skin.
DIAGNOSIS AND TESTING - HIGH - PRESSURE FUEL LINE LEAKS

Fig. 388: Typical Test For Leaks Using Cardboard

1 - HIGH-PRESSURE LINE
2 - CARDBOARD
3 - TYPICAL HIGH-PRESSURE FITTING
High-pressure fuel line leaks can cause starting problems and poor engine performance.
WARNING: Due to extreme fuel pressures of up to 180, 000 kPa (26, 107 psi), use
extreme caution when inspecting for high-pressure fuel leaks. Do not get
your hand or a finger near a suspected leak. Inspect for high-pressure
fuel leaks with a sheet of cardboard (2) (typical picture). High fuel
injection pressure can cause personal injury if contact is made with the
skin.
Start the engine. Move the cardboard (2) over the suspected high-pressure fuel line leak, and check for fuel
spray onto the cardboard. If line is leaking, retorque line while engine is shutdown. Replace damaged, restricted
or leaking high-pressure fuel lines with the correct replacement line.
CAUTION: The high-pressure fuel lines must be clamped securely in place in the
brace. The lines cannot contact each other or other components. Do not
attempt to weld high-pressure fuel lines or to repair lines that are
damaged. Only use the recommended lines when replacement of high-
pressure fuel line is necessary.
NOISE ISOLATORS

Fig. 389: Fuel Lines At Rail

Noise isolators (14) are used on the six high-pressure fuel lines. They should be positioned in the middle of the
horizontal or longest straight section of each fuel line. The split on each isolator should be facing downward. Be
sure the noise isolator is not touching another isolator or any other components.
REMOVAL
REMOVAL




2. Remove the engine oil dipstick (2).


Connector






10. Remove the CCV oil drains hoses (1, 2) from cylinder head cover.



12. Disconnect the fuel pressure sensor wire harness connector (2).
13. Disconnect necessary wiring harness retention clips from intake manifold.
14. Remove nut and bolt securing the oil dipstick tube.
15. Thoroughly clean fuel tubes at both ends.
CAUTION: When loosening or tightening high-pressure lines attached to a

separate fitting (13), use a back-up wrench on fitting (12). Do not
allow fittings (12) to rotate. Damage to both fuel line and fitting will
result.

16. If removing fuel tube at No. 6 cylinder, a bracket (5) is located above fuel tube connection at cylinder
head. Two bolts (4) secure this bracket to rear of cylinder head. The upper bolt hole is slotted. Loosen
(but do not remove) these two bracket bolts. Tilt bracket down to gain access to No. 6 fuel line
connection.
NOTE: Before fuel tubes No. 1 or No. 2 can be removed the intake manifold need
to be removed first. Remove the intake manifold. Refer to MANIFOLD,
INTAKE, REMOVAL, 6.7L .
17. If removing fuel tube at either No. 1 or No. 2 cylinder.

18. Place shop towels around fuel tubes at fuel rail and injectors. If possible, do not allow fuel to drip down
side of engine.
19. Carefully remove each fuel tube from engine. Note position of each while removing. Do not bend lines
while removing.
20. Remove the fuel return line banjo bolt at fuel rail and discard sealing washers.
INSTALLATION
INSTALLATION


1. Clean any dirt/debris from top of intake manifold and bottom of fuel rail.
2. Install fuel rail (11). Tighten bolts (12) to 24 N.m (18 ft. lbs.).

RESULT.


4. Connect the fuel pressure sensor harness connector (2).

5. Install the fuel tube silencer.






Connector



VALVE, FUEL PRESSURE LIMITING
OPERATION
OPERATION
Fuel pressure at the fuel rail is monitored by the fuel rail pressure sensor. If fuel pressure becomes excessive,
the pressure limiting valve opens and vents excess fuel pressure vents through the fuel pressure limiting valve
drain port.
REMOVAL
REMOVAL


Fig. 410: EGR Air Flow Control Valve Location

1. Remove the intake manifold (2). Refer to MANIFOLD, INTAKE, REMOVAL, 6.7L .

Fig. 411: Pressure Limiting Valve & Fuel Rail

2. Thoroughly clean area at pressure limiting valve (1).

3. Remove pressure limiting valve (1) from fuel rail (2).
INSTALLATION
INSTALLATION
Fig. 412: Pressure Limiting Valve & Fuel Rail

1. Be sure both end of manifold and limiting valve mounting area are clean.
2. Lubricate O-ring on pressure limiting valve with fresh diesel fuel. Also lubricate threads with fresh diesel
fuel.
3. Install the fuel pressure limiting valve (1). Tighten to 100 N.m (74 ft. lbs.).


4. Install the intake manifold (2). Refer to MANIFOLD, INTAKE, INSTALLATION, 6.7L .
5. Using a diagnostic scan tool, reset vale life by using the "Reset Two-Stage Dump Valve
Accumulator" function in the PCM portion of the diagnostic tool.
FUEL INJECTION, 6.7L 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 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.
SPECIFICATIONS
FUEL INJECTOR FIRING ORDER - DIESEL
The firing order for the Cummins turbo-diesel engine is 1-5-3-6-2-4 .
TORQUE - 6.7L
DESCRIPTION N.m Ft. Lbs. In. Lbs.

Crankshaft Position Sensor 10 - 89
Engine Cover Bolts 10 - 89
Fuel Injector Connector Nut at
15 -
Cylinder Head 133
Step 2 55 41 -
Fuel Control Actuator 7 - 62
Fuel Injector Bolts 8 - 71
Fuel Injector Solenoid Nuts 1.5 - 13
Intake Air Heater Bolts 24 18 -
Intake Air Heater Cable Nuts 10 - 89
Intake Air Heater Relay Cable
9 - 80
Nuts
Intake Air Heater Relay Screws 5 - 44
Intake Air Temperature Sensor 1 - 9
Intake Manifold Bolts 24 18 -
Mass Air Flow Sensor 1 - 9
No. 6 Fuel Tube Shield Bolts 43 32 -
Rocker Housing Bolt 24 18 -
TMap Sensor Screw 1 - 9
SPECIAL TOOLS
SPECIAL TOOLS

9010A - Remover/Installer, Fuel Injector

8848, 8849.)
9015 - Remover, High Pressure Connector

8848, 8849, 8849CC.)
ACTUATOR, FUEL CONTROL
DESCRIPTION
DESCRIPTION


The Fuel Control Actuator (FCA) (3) is located at the rear of the high-pressure, fuel injection pump.
OPERATION
OPERATION
The Fuel Control Actuator (FCA) is an electronically controlled solenoid valve. The Powertrain Control
Module (PCM) controls the amount of fuel that enters the high-pressure pumping chambers by opening and
closing the FCA based on a demanded fuel pressure. When the FCA is opened, the maximum amount of fuel is
being supplied to the fuel injection pump. Any fuel that does not enter the injection pump is directed to the
cascade overflow valve. The cascade overflow valve regulates how much excess fuel is used for lubrication of
the pump and how much is returned to the fuel tank through the drain manifold.
An audible click from the FCA is normal when operating the key from the ON to the OFF position.
REMOVAL
REMOVAL



3. Remove bolts (1 and the engine cover (3).

4. Disconnect the Fuel Control Actuator (FCA) harness connector (6).

5. Remove screws (1) and the FCA from injection pump.
INSTALLATION
INSTALLATION

1. Lubricate new Fuel Control Actuator (FCA) O-ring with clean oil.
2. Install FCA into the injection pump. Tighten screws (1) to 7 N.m (62 in. lbs.).


4. Install the engine oil dipstick (2).
HEATER, AIR INTAKE
OPERATION
OPERATION
The air heater element is used to heat incoming air to the intake manifold. This is done to help engine starting
and improve driveability with cool or cold outside temperatures.
Electrical supply for the air heater element is controlled by the Powertrain Control Module (PCM) through the
air heater relay. Refer to RELAY, INTAKE AIR HEATER for more information.
A heavy-duty cable connects the air heater element to the air heater relay. This cable will supply 12-volts to an
individual heating element within the heater block assembly.
The following chart displays the pre-heat, or turn-on times (in seconds) of the wait-to-start lamp. If the
intake manifold temperature is above 66.09 degrees Fahrenheit, the wait-to-start lamp will not
illuminate. Consequently, the intake air heater element will not be activated.
WAIT-TO-START LAMP TURN-ON TIMES

PRE-HEAT TIME PRE-HEAT TIME WITH BARO AT: (IN. HG.)
WITH INTAKE
MANIFOLD
TEMPERATURE AT: 19.99 IN. HG 23.00 IN. HG. 25.00 IN. HG. 26.99 IN. HG. 29.00 IN. HG.
(IN DEGREES ° F)
-40.00° F 75.0 seconds 75.0 seconds 30.0 seconds 30.0 seconds 30.0 seconds
0.00° F 10.0 seconds 10.0 seconds 10.0 seconds 10.0 seconds 10.0 seconds
REMOVAL

REMOVAL
Fig. 419: Air Intake Heater Assembly Components

NOTE: If servicing the heater element (1) is required, the entire air intake heater
assembly (2) must be replaced.



2. Remove the intake manifold (2). Refer to MANIFOLD, INTAKE, REMOVAL, 6.7L .
3. Remove fuel rail. Refer to RAIL, FUEL, REMOVAL.
Fig. 421: Identifying Intake Heater Cable Connection

4. Remove heater cable nut (2) and the heater cable from stud.
5. Disconnect fuel injector harness connectors (1) and (6).
6. Disconnect crankcase vent line (3) at top of valve cover.
7. Disconnect crankcase pressure sensor harness connector (5).


8. Remove bolts (4) and the air intake heater assembly (2).
9. Remove and discard gasket (5).
INSTALLATION
INSTALLATION


1. Clean all gasket mating surfaces.

2. Using a new gasket (5), install the air intake heater (2). Tighten bolts (4) to 24 N.m (18 ft. lbs.).
Fig. 424: Identifying Intake Heater Cable Connection


3. Connect crankcase pressure sensor harness connector (5).

4. Connect crankcase vent line (3) at top of valve cover.
5. Connect the fuel injector harness connectors (1) and (6).
6. Install the intake air heater cable onto stud. Tighten nut (2) 10 N.m (89 in. lbs.).
7. Install fuel rail. Refer to RAIL, FUEL, INSTALLATION.

8. Install intake manifold (2). Refer to MANIFOLD, INTAKE, INSTALLATION, 6.7L .

INJECTOR(S), FUEL
DESCRIPTION
DESCRIPTION

Fig. 426: Fuel Injector - Diesel

Six individual, solenoid actuated high-pressure fuel injectors are used (6). The injectors are vertically mounted
into a bored hole in the top of the cylinder head. This bored hole is located between the intake/exhaust valves.
Fig. 427: Removing/Installing Fuel Line Shield, High Pressure Fuel Lines, HPC Connector Tube, Fuel
Injectors & Bolts

High-pressure connectors (13), mounted into the side of the cylinder head, connect each fuel injector to each
high-pressure fuel tube (1).
OPERATION
OPERATION
High-pressure fuel is supplied from the injection pump, through a high-pressure fuel line, into a fuel rail,
through high-pressure lines, through steel connectors and into the solenoid actuated fuel injector. The
Powertrain Control Module (PCM) actuates the solenoid causing the needle valve to rise and fuel flows through
the spray holes in the nozzle tip into the combustion chamber.
Each fuel injector is connected to the fuel rail by a high-pressure fuel line and a steel connector. This steel
connector is positioned into the cylinder head and sealed with an O-ring. The connector is retained in the
cylinder head by a nut (fitting) that is threaded into the cylinder head.
The torquing force of this threaded nut (fitting) provides a sealing pressure between the fuel line connector and
the fuel injector. Retaining nut torque is very critical. If the nut (fitting) is under torqued, the mating surfaces
will not seal and a high-pressure fuel leak will result. If the fitting is over torqued, the connector and injector
will deform and also cause a high-pressure fuel leak. This leak will be inside the cylinder head and will not be
visible. The result will be a possible fuel injector miss-fire and low power, or a no-start condition.
The fuel injectors use hole type nozzles. High-pressure flows into the side of the injector, the PCM activates the
solenoid causing the injector needle to lift and fuel to be injected. The clearances in the nozzle bore are
extremely small and any dirt or contaminants will cause the injector to stick. Because of this, it is very
important to do a thorough cleaning of any lines before opening up any fuel system component. Always cover
or cap any open fuel connections before a fuel system repair is performed.
Each fuel injector connector tube contains an edge filter that is designed to break up small contaminants before
entering the fuel injector. The edge filters are not a substitute for proper cleaning and covering of all fuel
system components during repair.
The bottom of each fuel injector is sealed to the cylinder head with a 1.5 mm thick copper shim (gasket). The
correct thickness shim must always be re-installed after removing an injector.
Fuel pressure in the injector circuit decreases after injection. The injector needle valve is immediately closed
and fuel flow into the combustion chamber is stopped. Exhaust gases are prevented from entering the injector
nozzle by the needle valve.
REMOVAL
REMOVAL
CAUTION: Refer to Cleaning Fuel System Parts.

2. Remove cylinder head cover. Refer to COVER(S), CYLINDER HEAD, REMOVAL, 6.7L .

Fig. 429: Fuel Injector Wiring Harness Components

4. Remove all 12 fuel injector wire harness nuts (1) securing integrated wiring harness to all 6 fuel injectors
(2).
5. Remove the cylinder cover gasket.

6. Remove the high pressure fuel tubes. Refer to TUBE(S), FUEL, REMOVAL.
7. Remove the fuel injector connector nut (13).
Fig. 431: Tool #9015 & Connector Tube


8. Install the High Pressure Connector Remover (special tool #9015, Remover, High Pressure Connector)
(4) onto fuel injector connector tube located in cylinder head.
Fig. 432: Removing High Pressure Connector Tube

9. Using Thread High Pressure Connector Remover (special tool #9015, Remover, High Pressure
Connector) (2), pry and remove the fuel injector connector tube(s) (4) from the cylinder head.

Fig. 433: Fuel Injector & Mounting Bolts

10. Remove fuel injector hold-down clamp bolts (1).

11. Remove necessary intake and exhaust rocker arm assemblies.
Fig. 434: Rocker Housing Mounting Bolt

NOTE: The rocker housing support bridge is bolted to the top of cylinder head.
The mounting stud from Fuel Injector Removal/Installer (special tool

#9010A, Remover/Installer, Fuel Injector) was meant to temporarily replace

a rocker housing mounting bolt.
12. Remove the necessary rocker housing mounting bolt.
Fig. 435: Identifying Handle Nut, Tool Handle, Mounting Stud, Rocker Housing, Clamshell Halves,
Fuel Injector & Retainer Sleeve
CAUTION: Fuel Injector Removal/Installer is equipped with 2 clamshell clamps, a

sliding retainer sleeve to retain the clamshell clamps, a 2-piece
mounting stud and a pivoting handle. Do not attempt to remove the
fuel injectors with any other device. Damage to injector will occur.
13. Install and tighten 2-piece mounting stud (3) of Fuel Injector Removal/Installer (special tool #9010A,
Remover/Installer, Fuel Injector), to rocker housing (4). If removing the No. 6 fuel injector, separate the
2-piece mounting stud (3). Install lower half of mounting stud (3) to center of rocker housing bridge (4)
and upper half of mounting stud to lower half.
14. Position tool handle (2) to mounting stud (3) and install handle nut (1). Leave handle nut (1) loose to
allow a pivoting action.
15. Position lower part of clamshell halves (5) to sides of fuel injector (6) (wider shoulder to bottom). The
upper part of clamshell halves should also be positioned into machined shoulder on the handles (2)
pivoting head.
16. Slide the retainer sleeve (7) over pivoting handle head (2) to lock clamshell halves (5) together. Be sure
handle pivot nut (1) is loose.
17. Depress handle of Fuel Injector Removal/Installer (special tool #9010A, Remover/Installer, Fuel Injector)
(2) downward to remove fuel injector straight up from cylinder head bore.

Fig. 436: Fuel Injector Sealing Washer (Shim)

18. Remove and discard injector sealing washer (2). This washer should be located on tip of injector (1), or
may have remained in the injector bore.
Fig. 437: Measuring Injector Sealing Washer (Shim)

19. Measure injector sealing washer (1).
INSTALLATION
INSTALLATION

1. Inspect fuel injector :

Look for burrs on injector inlet.
Check nozzle holes for hole erosion or plugging.
Inspect end of nozzle for burrs or rough machine marks.
Look for cracks at nozzle end.
If any of these conditions occur, replace injector.
2. Inspect high-pressure fuel injector connector for :

Damaged tip.
Loose of missing alignment pin.
Cut or missing O-ring.
3. Thoroughly clean fuel injector cylinder head bore. Blow out bore hole with compressed air.
Fig. 438: Measuring Injector Sealing Washer (Shim)

4. The bottom of fuel injector is sealed to cylinder head bore with a copper sealing washer (shim) (1) of a
certain thickness. A new shim (1) with correct thickness must always be re-installed after removing
injector. Measure thickness of injector shim (1). Shim Thickness: 1.5 mm (.060")
5. Install new shim (1) (washer) to bottom of injector. Apply light coating of clean engine oil to washer.
This will keep washer in place during installation.
6. Install new O-ring to fuel injector. Apply small amount of clean engine oil to O-ring and injector bore.

Fig. 439: Fuel Injector & Mounting Bolts

7. Install injector into cylinder head with male (high-pressure) connector port facing the intake manifold.
Push down on fuel injector mounting flange to engage O-ring and seat injector.

8. Tightening Sequence:
Install fuel injector hold-down clamp (mounting flange) bolts. Be sure the clamp is perpendicular to
the injector body. Do a preliminary tightening of these bolts to 5 N.m (44 in. lbs.). This
preliminary tightening insures the fuel injector is seated and centered.
After tightening, relieve bolt torque, but leave both bolts threaded in place.
Install the fuel injector connector (14) and fuel injector connector nut (13). Do a preliminary
tightening of nut (12) to 15 N.m (133 in. lbs.).
Alternately tighten injector hold-down bolts to 8 N.m (71 in. lbs.).
Do a final tightening of the fuel injector connector nut (13). Tighten to 55 N.m (41 ft. lbs.).
Fig. 441: Rocker Housing Mounting Bolt

10. Install the necessary rocker housing mounting bolt (1) and tighten to 24 N.m (18 ft. lbs.).

Fig. 442: Fuel Injector Wiring Harness Components

11. Install the cylinder head cover gasket.

12. Connect fuel injector solenoid wires and nuts (1) to top of injectors. Tighten connector nuts to 1.50 N.m
(13 in. lbs.). Be very careful not to overtighten these nuts as damage to fuel injector will occur.
13. Install the intake and exhaust rocker arm assembly. Refer to ROCKER ARM, VALVE,
INSTALLATION, 6.7L .
14. Set exhaust valve lash. Refer to VALVES, INTAKE AND EXHAUST STANDARD PROCEDURE .


16. Install cylinder head cover. Refer to COVER(S), CYLINDER HEAD, INSTALLATION, 6.7L .

RELAY, INTAKE AIR HEATER
DESCRIPTION
DESCRIPTION
Fig. 444: Air Intake Heater Relay, Right Battery Tray & Fasteners
The air intake heater relay (3) is located in the engine compartment. It attached to a bracket located to the right
battery tray (1).
OPERATION
OPERATION
The Powertrain Control Module (PCM) operates the heating element through the intake manifold air heater
relay. Refer to the appropriate Electrical Diagnostics article for an electrical operation and complete description
of the intake heater, including pre-heat and post-heat cycles.
REMOVAL
REMOVAL

Fig. 445: Air Heater & Components


2. Disconnect relay trigger wires (4) at relays. Note position of wiring before removing.
3. Remove nuts (2) at cable connectors and disconnect cables (1 and 3) from mounting studs. Note position
of cables before removing.

4. Remove screws (2) and the relay assembly (3).
INSTALLATION
INSTALLATION

1. Install the intake air heater relay (3). Tighten screws (2) to 5 N.m (44 in. lbs.).
Fig. 448: Air Heater & Components


2. Install cables (1 and 3) to mounting studs. Tighten nuts (2) 9 N.m (80 in. lbs.).
3. Connect relay trigger wires (4) at relays.
SENSOR, PTO SWITCH
DESCRIPTION
DESCRIPTION
This Powertrain Control Module (PCM) input is used only on models equipped with aftermarket Power Take
Off (PTO) units.
OPERATION
OPERATION
This input is used only to tell the Powertrain Control Module (PCM) that the aftermarket PTO (Power Take
Off) unit has been engaged. The PCM will disable (temporarily shut down) certain OBD II diagnostic trouble
codes when the PTO unit is engaged.
SENSOR, ACCELERATOR PEDAL POSITION
DESCRIPTION
DESCRIPTION
Fig. 449: Accelerator Pedal Position Sensor, Electrical Connector, Accelerator Pedal & Fasteners

1 - APPS
The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator
pedal assembly (3).
OPERATION
OPERATION
The Accelerator Pedal Position Sensor (APPS) provides the Powertrain Control Module (PCM) with two DC
voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals
will be half the voltage of the other signal.
REMOVAL
REMOVAL

1 - APPS



2. Disconnect the Accelerator Pedal Position Sensor (APPS) wire harness connector (2).
3. Remove the APPS lower mounting bolt (4) and two mounting nuts.
4. Remove the pedal and APPS assembly (3) from vehicle.
INSTALLATION
INSTALLATION

1 - APPS
1. Install pedal and Accelerator Pedal Position Sensor (APPS) assembly (3).
2. Install APPS two mounting nuts and lower mounting bolt (4) and securely tighten.

3. Connect the APPS wire harness connector (2).

SENSOR, TMAP-INTAKE MANIFOLD
DESCRIPTION
DESCRIPTION
Fig. 452: TMAP Sensor, Wire Harness Connector & Bolt

The TMAP combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into
the top of the intake manifold with the sensor element extending into the air stream.
OPERATION
OPERATION
The IAT portion of the sensor provides an input voltage to the Powertrain Control Module (PCM) indicating
intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the PCM
indicating turbocharger boost pressure.
REMOVAL
REMOVAL





Connector









12. Clean the area around TMAP sensor (4).

13. Disconnect the TMAP sensor wire harness connector (3).
14. Remove screw (5) and the TMAP sensor (4).
INSTALLATION
INSTALLATION


1. Check condition of TMAP sensor O-ring.

2. Clean sensor mounting area at intake manifold.
3. Lubricate TMAP sensor O-ring and sensor mounting hole in intake manifold cover with clean engine oil.
4. Install the TMAP sensor (2) into intake manifold. Tighten screw (1) to 1 N.m (9 in. lbs.).
5. Connect TMAP sensor wire harness connector (3).

6. Install the fuel tube silencer (1).






Connector



15. Install the engine oil dipstick (2).
SENSOR, AIR TEMPERATURE, INTAKE
OPERATION
OPERATION
The Inlet Air Temperature/Pressure Sensor is a combination dual-function sensor. The sensor element extends
into the intake air stream at the top of the air filter housing. Ambient air temperature as well as barometric
pressure is monitored by this sensor. The Powertrain Control Module (PCM) monitors signals from this sensor.
REMOVAL
REMOVAL

Fig. 471: Intake Air Temperature/Pressure Sensor & Mass Airflow Sensor
The Inlet Air Temperature/Pressure Sensor (2) is located on the air cleaner cover.

2. Disconnect the intake air temperature sensor wire harness connector (6).
3. Remove screw (1) and the intake air temperature sensor (2) from air cleaner cover.
INSTALLATION
INSTALLATION


2. Position sensor (2) into top of air cleaner cover with a slight twisting action.
3. Install the intake air temperature sensor (2). Tighten screw (1) to 1 N.m (9 in. lbs.).
4. Install the intake air temperature sensor wire harness connector (6).
SENSOR, CRANKSHAFT POSITION
DESCRIPTION
DESCRIPTION
Fig. 473: Crankshaft Position Sensor

The Crankshaft Position Sensor (CKP) is attached at the left side front of the engine next to the crankshaft
damper.
OPERATION
OPERATION

The CKP contains a hall effect device. A rotating, notched target wheel (tone wheel) for the CKP is located
behind the engine harmonic balancer (2). This hall effect device detects notches located on the tone wheel. As
the tone wheel rotates, the notches pass the tip of the CKP.
When the leading edge of the tone wheel notch passes the tip of the CKP, the following occurs: The interruption
of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts.
When the trailing edge of the tone wheel notch passes the tip of the CKP, the following occurs: The change of
the magnetic field causes the signal voltage to switch low to 0 volts.
The Camshaft Position Sensor (CMP) also provides a signal to the Powertrain Control Module (PCM) at all
times when the engine is running. The PCM uses this CMP information primarily on engine start-up. Once the
engine is running, the PCM uses the CMP as a backup sensor for engine speed.
REMOVAL
REMOVAL



3. Disconnect Crankshaft Position (CKP) sensor wire harness connector (1).
Fig. 476: Crankshaft Position Sensor & Bolt

4. Remove bolt (2) and the CKP sensor (1).
INSTALLATION
INSTALLATION

Fig. 477: Crankshaft Position Sensor & Bolt

1. Install the Crankshaft Position (CKP) sensor (1). Tighten bolt (2) to 10 N.m (89 in. lbs.).

2. Connect the CKP sensor wire harness connector (1).

SENSOR, MASS AIRFLOW (MAF)
DESCRIPTION
DESCRIPTION

The Mass Airflow Sensor (4) is located on the air cleaner cover (7).
OPERATION
OPERATION
The Mass Airflow (MAF) sensor is a frequency based device. A constant voltage is applied to a heated wire on
the sensor. This wire is positioned in the air cleaner air stream and is heated by the electrical current that the
voltage produces. As air flows across it, it cools down. The heated wire or film is a positive temperature
coefficient resistor. This means that its resistance drops when its temperature drops. The drop in resistance
allows more current to flow through it in order to maintain the programmed temperature. This current is
changed to a frequency which is sent to the Powertrain Control Module (PCM) and interpreted as air flow.
Adjustments for air temperature and humidity are taken into consideration because they also affect the
temperature of the heated wire or film.
REMOVAL
REMOVAL


2. Disconnect the Mass Air Flow (MAF) sensor harness connector (5).
3. Remove screw (3) and the MAF sensor (4) from the air cleaner cover (7).
INSTALLATION
INSTALLATION

1. Check the condition of the sensor O-ring.

2. Install the Mass Air Flow (MAF) sensor (4) into top of the air cleaner (7). Tighten screw (3) to 1 N.m (9
in. lbs.).
3. Connect the MAF sensor wire harness connector (5).

ENGINE Fuel System - Ram Pickup

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ENGINE Fuel System - Ram Pickup

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2014 RAM 3500 HD Laramie

2014 ENGINE Fuel System - Ram Pickup

Fuel System - Ram Pickup

FUEL DELIVERY, GAS

DRAINING FUEL TANK

Fig. 1: Fuel Supply Line Quick Connect Fitting At Fuel Rail

Thursday, November 16, 2017 19:32:34

Fig. 2: Fuel Line Adapters

Thursday, November 16, 2017 19:32:21 Page 2

Fig. 4: Fuel Pump Module

FUEL SYSTEM PRESSURE RELEASE

1. Remove the fuel fill cap.

Thursday, November 16, 2017 19:32:21 Page 3

Fig. 5: Fuel Supply Line Quick Connect Fitting At Fuel Rail

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

FUEL SYSTEM PRESSURE-GAS

58 psi +/- 2 psi

Liquid Gas Fuel Pressure at Fuel Rail 58 psi +/- 2 psi

Thursday, November 16, 2017 19:32:21 Page 4

Compressed Natural Gas Fuel Pressure after

DESCRIPTION N.m Ft. lbs. In. lbs.

Thursday, November 16, 2017 19:32:21 Page 5

9340 - SAE Fuel Pump Lock Ring

FITTING, QUICK CONNECT

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

STANDARD PROCEDURE - QUICK-CONNECT FITTINGS

Thursday, November 16, 2017 19:32:21 Page 6

These are the quick-connect fittings:

Redundant Latch Single Button Type Fitting

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

REDUNDANT LATCH SINGLE BUTTON TYPE FITTING:

Thursday, November 16, 2017 19:32:21 Page 7

Fig. 6: Redundant Latch & Push Button

Fig. 7: Redundant Latch & Internal Latches

Thursday, November 16, 2017 19:32:21 Page 8

SINGLE BUTTON TYPE FITTING:

Fig. 8: Single Button Fitting

Fig. 9: Ouick-Connect Fitting Latches

Thursday, November 16, 2017 19:32:21 Page 9

2 BUTTON TYPE FITTING

Fig. 10: 2-Button Type Fitting

PINCH TYPE FITTING

Thursday, November 16, 2017 19:32:21 Page 10

Fig. 11: Pinch Type Quick-Connect Fitting

SINGLE TAB TYPE FITTING

Fig. 12: Single-Tab Type Fitting

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Fig. 13: Disconnecting Single-Tab Type Fitting

TWO TAB TYPE FITTING

Thursday, November 16, 2017 19:32:21 Page 12

Fig. 14: Typical Two-Tab Type Quick-Connect Fitting

PLASTIC RETAINER RING TYPE FITTING

Fig. 15: Plastic Retainer Ring Type Fitting

Thursday, November 16, 2017 19:32:21 Page 13

LATCH CLIP TYPE 1 FITTING

Fig. 16: Latch Clip Type 1

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

Thursday, November 16, 2017 19:32:21 Page 14

Fig. 17: Fuel Line Disconnection Using Special Tool

LATCH CLIP TYPE 2 FITTING

Thursday, November 16, 2017 19:32:21 Page 15

Fig. 18: Latch Clip Type 2

Fig. 19: Fuel Line Disconnection Using Special Tool

WING TYPE FITTING