Fuel System

Overview

—

TORQUE SPECIFICATIONS CHART

DESCRIPTION	N.m	Ft. Lbs.	In. Lbs.
Accelerator Pedal	12	-	105

Bracket Mounting Nuts Crankshaft Position 28 21 - Sensor - 3.7L Fuel Filler Hose Clamp at 3 - 30 Tank Fuel Filler Housing-to- 2 - 17 Body Screws

Fuel Filler Tube Clamp	3.5	-	30
Fuel Rail Mounting Bolts	11	-

- 3.7L Fuel Tank Mounting 61 45 - Strap Bolts Map Sensor Mounting 3 - 25 Screws Throttle Body Mounting 7.5 - 65 Bolts - 3.7L Oxygen Sensors 41 30 -

FUEL DELIVERY - GAS

FUEL DELIVERY SYSTEM

Fuel is picked up in the fuel tank by the fuel pump module. This module is located on the bottom of the fuel tank.

A fuel return system is provided within the fuel pump module using check valves. A separate fuel return line from the engine to the tank is not used.

The fuel pressure regulator and the main fuel filter are combined within the fuel pump module.

The fuel tank assembly consists of: the fuel tank, fuel pump module assembly, fuel pump module lock ring/gasket, ORVR components. Refer to DESCRIPTION .

A fuel filler/vent tube assembly using a pressure/vacuum, 1/4 turn fuel filler cap is used. A one-way check valve is installed into the tanks fuel fill fitting.

Also to be considered part of the fuel system is the evaporation control system and ORVR system. This is designed to reduce the emission of fuel vapors into the atmosphere.

Both fuel filters are designed for extended service. They do not require normal scheduled maintenance.

See STANDARD PROCEDURE.📷 1

WARNING: The fuel system may be under a constant pressure (even with the engine off). Before servicing any fuel system hoses, fittings, lines, or most components, fuel system pressure must be released. Refer to the FUEL SYSTEM PRESSURE RELEASE procedure.

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.

FITTING-QUICK CONNECT

FUEL PRESSURE REGULATOR

The fuel pressure regulator is located within the fuel pump module. It is serviced by replacing the fuel pump module assembly.

PUMP-FUEL

HIGH FUEL SYSTEM PRESSURE📷 1

WARNING: High-pressure fuel lines deliver fuel under extreme pressure from the injection pump to the injectors. This may be as high as 1600 bar (23,200 psi). Use extreme caution when inspecting for high-pressure fuel leaks. Fuel under this amount of pressure can penetrate skin causing personal injury or death. Inspect high-pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system.

D & T HIGH PRESSURE LEAKS📷 1

1 - HIGH-PRESSURE LINE 2 - CARDBOARD 3 - FITTING

WARNING: High-pressure lines deliver diesel fuel under extreme pressure from the injection pump to the fuel injectors. This may be as high as 160,000 kPa (23,206 psi). Use extreme caution when inspecting for high-pressure fuel leaks. Fuel under this amount of pressure can penetrate skin causing personal injury or death. Inspect for high-pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system.

High-pressure fuel leaks can cause starting problems and poor engine performance.

Carefully place a piece of cardboard (2) over the high-pressure fuel lines or suspected area. Move your body and hands away from the area. Start the engine and run till warm. TURN THE ENGINE OFF . Inspect the piece of cardboard for witness marks. If a high-pressure line connection is leaking, replace damaged, restricted or leaking high-pressure fuel lines with the correct replacement line.

CAUTION: The high-pressure fuel 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.

LOW-PRESSURE LINES📷 1

Fuel supply line restrictions or a restricted fuel filter can cause starting problems and prevent engine from accelerating. The starting problems include; no start, longer cranking times, low power and/or white fog like exhaust.

Inspect all fuel supply lines for restrictions or blockage, including the fuel filter. Flush or replace as necessary.

HIGH-PRESSURE LINES

CAUTION: High-pressure lines cannot contact each other or other components. Do not attempt to weld high-pressure fuel lines or to repair lines that are damaged. High-pressure lines can be reused only after close inspection for cracks or deformation around the sealing cone. Corroded pipes must be replaced. Use only recommended lines when replacement of high- pressure fuel line is necessary.

NOTE: High-pressure fuel lines must be replaced at each disassembly.

Restricted (kinked or bent) high-pressure lines can cause starting problems, poor engine performance, engine misfire and white smoke from exhaust.

CLEANING FUEL SYSTEM COMPONENTS

CAUTION: Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high- pressure fuel lines, fuel rail, 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. DO NOT wire brush injector nozzles when cleaning. 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.

TORQUE-2.8L DIESEL📷 1

DESCRIPTION N.m Ft. Lbs. In. Lbs. Fuel Filter Housing 10 - 89 Bleeder Screw Crankshaft Position 11 - 97 Sensor Bolt Crankshaft Position 11.8 - 104 Sensor Shield Bolt Boost Pressure/Intake Air 11.8 - 104 Temperature Sensor Bolts Return Fuel Junction 10.8 - 96 Block at Intake Manifold Fuel Filter 18 - 159 Fuel Filter Screw to 30 22 - Housing

High Pressure Injection 24.5 18 - Pump Nuts Fuel Line Fittings at 24 17 - Pump Fuel Rail Sensor 35 25 - Fuel Line Fittings at 35 25 - Filter Housing High Pressure Injection 88.3 65 - Pump Sprocket Nut Fuel Injector Retaining 32.4 24 - Bolts High Pressure Fuel Lines 28 20 247 at High Pressure Pump

Fuel Injector Fuel Lines	5	-	44
at Fuel Rail	PLUS 75° TURN
High Pressure Fuel Feed	5	-	44
Line at Fuel Rail	PLUS 75° TURN

Fuel Injector Lines at the 28 20 247 Fuel Injectors

Fuel Rail Bolts	24.5	18	-
Fuel Pressure Sensor	35	26	-
Water In Fuel Sensor	1.2	-	10

Fuel Water/Separator 24.5 24 - Mounting Nuts

Fuel Line Hose Clamp	14.7	11	62
Fuel Quantity Solenoid	11	-	97
Fuel Tank Bolts	61	45	-
Fuel Filler Tube Clamp	3.5	-	30
APP Sensor	11	-	97

Fuel Pressure Solenoid Refer to the installation Procedure. Mounting Nut

SEPARATOR-FUEL FILTER/WATER

WATER-IN-FUEL (WIF) SENSOR - ECM INPUT📷 1

The combination drain valve/Water-In-Fuel (WIF) sensor (6) is located on the bottom of the fuel filter/water separator filter canister.

WATER-IN-FUEL (WIF) SENSOR - ECM INPUT📷 1

The sensor sends an input to the Engine Control Module (ECM) when it senses water in the fuel filter/water separator. As the water level in the filter/separator increases, the resistance across the WIF sensor decreases. This decrease in resistance is sent as a signal to the ECM and compared to a high water standard value. Once the value reaches 30 to 40 kilohms, the ECM will activate the water-in-fuel warning lamp through CAN bus circuits. This all takes place when the ignition key is initially put in the ON position. The ECM continues to monitor the input while the engine is running.

WATER-IN-FUEL (WIF) SENSOR📷 1

The Water-In-Fuel (WIF) sensor is located at the bottom of fuel filter/water separator canister. Refer to SEPARATOR-FUEL FILTER/WATER for removal and installation procedures.

HEATER - FUEL

WATER-IN-FUEL (WIF) SENSOR📷 1

The fuel heater is located in the fuel filter/water separator canister housing. Refer to SEPARATOR-FUEL FILTER/WATER for removal and installation procedures.

RELAY - FUEL HEATER📷 1

Removal

The fuel heater relay (1) is located in the left/rear of the engine compartment.

Disconnect negative battery cable.

Disconnect electrical connector (2) from relay.

Remove relay mounting bolt and remove relay.

Check condition of relay connector pins for corrosion, etc.

Installation

The fuel heater relay (1) is located in the left/rear of the engine compartment.

Check condition of relay connector pins for corrosion, etc.

Position relay and install mounting bolt.

Connect electrical connector (2) to relay.

Connect negative battery cable to battery.

SENSOR - FUEL TEMPERATURE

WATER-IN-FUEL (WIF) SENSOR📷 1

The fuel temperature sensor is located in the fuel filter/water separator canister housing. Refer to SEPARATOR-FUEL FILTER/WATER for removal and installation procedures.

DAMAGE TO BOTH FUEL LINE AND FITTING WILL RESULT.📷 3

5. Disconnect fuel line fittings (2) and (4) and remove four fuel lines (3). Note and mark position of each fuel line while removing. 6. Remove fuel line clamp bolt (10). 7. Disconnect rail-to-injection pump high-pressure fuel line fittings (9) and (11) and remove fuel line (12). Note and mark position of fuel line while removing.

8. Remove three fuel rail mounting nuts (4). 9. Remove rail (2) from cylinder head.

Installation

NOTE: New High Pressure Fuel Line must be used any time the High Pressure Fuel Lines have been removed.

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.

Position fuel rail (2) to cylinder head.

Install three fuel rail mounting nuts (4). Tighten nuts (alternately) to 24 N.m (18 ft. lbs.) torque.

DAMAGE TO BOTH FUEL LINE AND FITTING WILL RESULT.📷 1

3. Install the injectors (8), the injector clamps (7) and washers (6). 4. Install the injector bolts (5). Do not tighten at this time. 5. Position and connect the high pressure line (12) between the high pressure injection pump and the fuel rail. Do not tighten at this time. 6. Torque injector clamp bolts to 32.4 Nm (23 ft. lbs.). 7. Torque the rail side (4) of the high pressure lines between the injectors and the fuel rail to 5 Nm (44 in. lbs.) plus an additional 75°. 8. Torque the injector side (2) of the high pressure lines between the injectors and the fuel rail to 28 Nm (20 ft. lbs.). 9. Torque the rail side (9) of the high pressure fuel line between the high pressure injection pump and the fuel rail to 5 Nm (44 in. lbs.) plus an additional 75°. 10. Torque the high pressure pump side (11) of the high pressure fuel line between the high pressure injection pump and the fuel rail to 28 Nm (20 ft. lbs.). 11. Install fuel line clamp bolt (10). Tighten bolt to 15 N.m (11 ft. lbs.) torque.

 12.   Connect electrical connectors to fuel injectors.
 13.   Connect electrical connector to fuel pressure solenoid (3).
 14.   Connect electrical connector to fuel pressure sensor (1).
 15.   Install the engine cover.
 16.   Connect negative battery cable to battery.

LINES-FUEL📷 1

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 line from each fuel injector. 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 four fuel lines from fuel rail up to the fuel injectors

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 160,000 kPa (23,206 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.

HIGH-PRESSURE FUEL LINES

High-Pressure Lines

CAUTION: The high-pressure fuel 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.

High-pressure fuel lines deliver fuel (under pressure) of up to approximately 160,000 kPa (23,206 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.

HIGH-PRESSURE FUEL LINE LEAK TEST

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 160,000 kPa (23,207 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.

HIGH-PRESSURE FUEL LINES📷 1

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.

1. Disconnect negative battery cable at battery. Isolate end of cable. 2. Remove dress-up cover from top of engine.

DAMAGE TO BOTH FUEL LINE AND FITTING WILL RESULT.📷 1

3. Disconnect fuel line fittings (2) and (4) and remove four fuel lines (3). Note and mark position of each fuel line while removing. 4. Remove fuel line clamp bolt (10).

5. Disconnect rail-to-injection pump high-pressure fuel line fittings (9) and (11) and remove fuel line (12). Note and mark position of fuel line while removing.

HIGH-PRESSURE FUEL LINES📷 1

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.

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.

LINE AND FITTING WILL RESULT.

1.   Position the injectors with the clamp and washer into the cylinder head seat.
  2.   Hand tighten the injector clamp bolts.
  3.   Install the high pressure fuel line.
  4.   Hand tighten the high pressure fuel line.
  5.   Torque the fuel injector clamp bolts to 32 Nm (23 ft. lbs.).
  6.   Torque the high pressure fuel rail nuts to 25 Nm (221 in. lbs.).
  7.   Torque the high pressure fuel line on the fuel injector to 28 Nm (247 in. lbs.).
  8.   Torque the high pressure fuel line on the fuel rail to 5 Nm (44 in. lbs) +75 degrees.

FUEL INJECTION PUMP📷 1

1 - FUEL INJECTION PUMP 2 - FUEL QUANTITY SOLENOID

A radial, 3 piston pump (1) mounted to the timing belt cover, is used to deliver fuel under high pressure to the fuel rail. See WARNING.

The pump is driven by the timing belt. Pressure is generated independently of the injection process. The pump is lubricated with diesel fuel and is not responsible for fuel injection timing. However, there is a mark on the high pressure fuel pump sprocket that must be aligned with a mark on the timing belt cover whenever the high pressure pump, sprocket, or timing belt have been removed.

FUEL INJECTION PUMP📷 1

High Pressure Pumping Plungers

The fuel quantity solenoid supples three high pressure pumping chambers. The pumping chambers have one way inlet valves that allow fuel to flow into the chambers. The valves then close during compression of the fuel and cause the high pressure fuel to overcome a ball and angled seat outlet valve.

All three pumping chambers are tied together in one circuit internal to the pump and provide high pressure fuel up to 1600 bar (23,000 psi) through a steel line, to the fuel rail.

The pump is driven at 1:1 engine speed and is not responsible for injection timing. The pump is only responsible for providing high pressure fuel while the ECM controls the injection timing.

FUEL INJECTION PUMP📷 3

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.

WARNING: High-pressure lines deliver diesel fuel under extreme pressure from the injection pump to the fuel injectors. Use extreme caution when inspecting for high-pressure fuel leaks. Fuel under this amount of pressure can penetrate skin causing personal injury or death. Inspect for high-pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system.

  1.   Disconnect negative battery cable.
  2.   Drain engine coolant.
  3.   Raise and support vehicle.
  4.   Disconnect and reposition engine coolant hose near rear of injection pump.
  5.   Remove timing belt.

6. Remove injection pump sprocket mounting nut (2). Attach a typical 3-jaw gear/sprocket puller such as special tool 1023 and remove sprocket (1) from pump.

7. Disconnect high-pressure fuel line (4) at rear of pump by removing banjo bolt. 8. Disconnect high-pressure fuel line (2) at rear of pump by removing fitting at end of line. 9. Disconnect electrical connector at high-pressure fuel sensor (1).

1 - FUEL INJECTION PUMP 2 - FUEL QUANTITY SOLENOID

10. Remove fuel injection pump mounting nuts (2). 11. Slide pump rearward from mounting studs.

FUEL INJECTION PUMP📷 3

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.

1 - FUEL INJECTION PUMP 2 - FUEL QUANTITY SOLENOID

1. Slip pump (1) over mounting studs. 2. Be sure pump is fully seated before tightening mounting nuts. Tighten injection pump mounting nuts

(2) to 24 N.m (18 ft. lbs.) torque.

3. Position sprocket (1) to pump shaft and install nut (2) finger tight.

4. Install banjo bolt for fuel line (4) at rear of injection pump. Tighten bolt to 28 N.m (20 ft. lbs.) torque. 5. Install fuel line (2) and fitting to rear of injection pump. Tighten fitting to 28 N.m (20 ft. lbs.) torque. 6. Connect electrical connector to high-pressure fuel sensor (1).

  7.   Tighten injection pump sprocket nut (4) to 88 N.m (65 ft. lbs.) torque.
  8.   PUMP ALIGNMENT MARKS: Rotate pump gear (1) until marks (2) and (3) are aligned.
  9.   Install timing belt.
 10.   Connect engine coolant hose near rear of injection pump.
 11.   Fill engine cooling system.
 12.   Lower vehicle.
 13.   Connect negative battery cable.
 14.   Start engine and check for fuel leaks.

PUMP-FUEL TRANSFER

FUEL TRANSFER (LIFT) PUMP📷 1

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 Engine Control Module (ECM).

FUEL TRANSFER PUMP📷 1

The fuel transfer pump (fuel lift pump) is a part of the fuel tank module. It is not serviced separately.

SENSOR-FUEL PRESSURE

FUEL PRESSURE SENSOR📷 1

WARNING: High - pressure fuel line deliver diesel fuel under extreme pressure from the injection pump to the fuel injectors. This may be as high as 1600 bar (23,200 psi). Use extreme caution when inspecting for high - pressure fuel leaks. Fuel under this amount of pressure can penetrate skin causing personal injury or death. Inspect for high - pressure leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system.

The fuel rail pressure sensor (1) screws into the fuel rail (2) at the top of the engine. The ECM uses this sensor to monitor the fuel rail pressure.

FUEL PRESSURE SENSOR📷 1

Review the high pressure fuel system warning. See WARNING.

The fuel flows to the fuel pressure sensor through an opening in the rail, the end of which is sealed off by the sensor diaphragm. Pressurized fuel reaches the sensor's diaphragm through a blind hole. The sensor element

(semiconductor device) converts the pressure to an electric signal is mounted on this diaphragm. The signal generated by the sensor is monitored by the ECM.

FUEL PRESSURE SENSOR

1. Disconnect negative battery cable. 2. Remove engine cover.

WARNING: High pressure fuel spray can cause severe cuts, and is extremely flammable. Before opening any part of the high pressure fuel system, wait for a minimum of 30 seconds after turning off the engine to allow pressure to bleed down from the high pressure side of the fuel system. Otherwise severe personal injury can result when the high pressure fuel system is opened.

WARNING: No sparks, open flames or smoking. Risk of poisoning from inhaling and swallowing fuel. Risk of injury to eyes and skin from contact with fuel. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing.

NOTE: Do allow cleaning solvent or debris to enter the fuel pressure sensor harness connector.

3. Clean the area around the fuel pressure sensor with Mopar® Throttle Body Cleaner P/N 04897156AA or equivalent degreasing solvent and compressed air. 4. Disconnect fuel pressure sensor electrical connector.

WARNING: When working with parts on the high side of the fuel injection system such as the fuel rail and high pressure injector lines, slowly loosen the part to allow any residual pressure to bleed down from the high pressure side of the system.

NOTE: Do not touch the connector terminals of the fuel rail pressure sensor. The internal electronic components of the sensor can be damaged.

5. Remove fuel pressure sensor (1) from fuel rail. 6. If the sensor is to be reused, remove the fuel rail pressure sensor sealing ring. Do not damage or gouge the fuel rail pressure sensor threads. If any gouges or cuts are present in the fuel rail pressure sensor threads, the sensor must be replaced. Otherwise, fuel leaks can occur.

NOTE: Do not allow dirt or debris to enter the fuel rail and fuel rail solenoid threads after the fuel pressure solenoid has been removed from the fuel rail.

7. Clean the thread and fuel pressure sensor sealing surface of the fuel rail. 8. Use a clean plug to close off the fuel rail pressure sensor opening if the fuel pressure solenoid will not be immediately reinstalled.

FUEL PRESSURE SENSOR📷 1

WARNING: Diesel fuel is under extreme pressure in the high pressure side of the fuel

injection system between the fuel injectors and the high pressure fuel pump. This may be as high as 1600 bar (23,200 psi.). Use extreme caution when inspecting for leaks in the high pressure side of the fuel injection system. Fuel under this amount of pressure can penetrate skin causing personal injury or death. Inspect for high pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing the high pressure side of the fuel system.

1. If reusing an existing fuel pressure sensor, install a new fuel pressure sensor sealing ring. 2. Lubricate the fuel pressure sensor threads and sealing ring with clean diesel fuel. 3. Install fuel pressure sensor (1) in fuel rail (2). Position the fuel rail pressure sensor so the harness connector is not stretched or under tension. Tighten sensor to 100 N.m (73 ft. lbs.). 4. Connect fuel pressure sensor electrical connector. 5. Install engine cover. 6. Connect negative battery cable.

SOLENOID-FUEL PRESSURE

FUEL PRESSURE SOLENOID📷 1

The fuel pressure solenoid (3) is attached to the rear of the fuel rail (2). The tip of the fuel pressure solenoid (3) uses a knife edge, for metal to metal sealing. The knife edge actually deforms the metal in the fuel rail in order to seal the surfaces. The solenoid must be replaced when ever it is removed from the rail. The solenoid controls and maintains constant rail pressure with a control current transmitted by the engine control module (ECM).

FUEL PRESSURE SOLENOID📷 2

1 - BALL SEAT 2 - SPRING FORCE 3 - MAGNETIC FORCE 4 - COIL 5 - FUEL PRESSURE SOLENOID 6 - HIGH PRESSURE SUPPLY

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

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

FUEL PRESSURE SOLENOID📷 1

Review the high pressure fuel system warning before beginning repair. See WARNING.

1. Disconnect negative battery cable.

NOTE: Do allow cleaning solvent or debris to enter the fuel pressure solenoid harness connector.

2. Clean the area around the fuel pressure solenoid with Mopar® Throttle Body Cleaner P/N 04897156AA or equivalent degreasing solvent and compressed air. 3. Disconnect the fuel pressure solenoid harness connector.

4. Remove fuel rail. See REMOVAL. 5. Clamp fuel rail (2) securely in vise with protective jaws.

CAUTION: Once removed, the solenoid must always be replaced. Do not reuse a fuel pressure solenoid that has been installed in the fuel rail.

6. Counterhold the fuel rail and unscrew the fuel pressure solenoid (3).

NOTE: Do not allow dirt or debris to enter the fuel rail and fuel rail solenoid threads after the fuel pressure solenoid has been removed from the fuel rail.

7. Use a clean plug to close off the fuel rail pressure solenoid opening if the fuel pressure solenoid will not be immediately reinstalled.

FUEL PRESSURE SOLENOID📷 1

Review the high pressure fuel system warning before beginning repair. See WARNING.

WARNING: Before working on an open fuel system, eliminate any source of sparks or open flames near the work area, and do not smoke. Wash diesel fuel off skin as soon as possible to avoid the risk of poisoning from inhaling and swallowing fuel. Do not allow diesel fuel to come in contact with eyes, otherwise, severe injury can result from contact with fuel. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing whenever possible to avoid injury.

CAUTION: There is a special tightening procedure for the fuel rail solenoid that must be followed along with the proper use of a torque wrench. Therefore the fuel rail must be removed before installing the fuel pressure solenoid.

CAUTION: Do not reuse an existing fuel pressure solenoid. A new fuel pressure solenoid must be installed any time the existing solenoid has been removed from the fuel rail.

1. Position the fuel rail (2) into a soft jawed vise. 2. Inspect the sealing surfaces of the fuel pressure solenoid opening in the fuel rail. If any cuts or gouges are present in the fuel rail pressure solenoid opening, replace the fuel rail. 3. Lubricate the fuel pressure solenoid sealing rings with clean diesel fuel. Do not allow dirt or debris to come in contact with the fuel rail solenoid or the threads in the fuel rail.

4. Manually thread the fuel pressure solenoid (3) into the fuel rail until hand tight. 5. Position the fuel pressure solenoid electrical socket so the fuel pressure solenoid harness connector is not under stress. Otherwise, the connector or harness can be damaged. 6. Counterhold the fuel rail, and tighten the fuel rail solenoid (3) as follows:  Tighten the fuel pressure solenoid to 60 N.m (44 ft. lbs.)

 Loosen the fuel pressure solenoid 90 degrees.

 Retighten the fuel pressure solenoid to 85 N.m (62 ft. lbs.).

7. Install fuel rail. See INSTALLATION. 8. Connect negative battery cable. 9. Start engine, allow to warm, turn engine off and inspect for leaks. See DIAGNOSIS AND TESTING.

SOLENOID - FUEL QUANTITY

FUEL QUANTITY SOLENOID📷 1

1 - FUEL SUPPLY TO FUEL RAIL 2 - HIGH PRESSURE FUEL PUMP 3 - FUEL QUANTITY SOLENOID

The fuel quantity solenoid is located in the back of the high pressure pump. The solenoid is pulse width modulated by the ECM and meters the amount of fuel that flows into the high pressure elements inside of the high pressure pump. The solenoid is also inactive during the first 30 seconds to allow maximum fuel pressure to the fuel rail during start up. See Fig. 79.

FUEL QUANTITY SOLENOID📷 1

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

The fuel quantity solenoid is commanded open by the ECM to allow the high pressure pump to build maximum pressure (1600 BAR, 23,200 PSI). See WARNING. The solenoid also has fuel tank heat protection function that meters the exact amount of fuel to prevent excess heated fuel from returning to the fuel tank

FUEL QUANTITY SOLENOID📷 1

1 - EGR AIR CONTROL VALVE 2 - GEAR SUPPLY PUMP 3 - FUEL QUANTITY SOLENOID

  1.   Disconnect the negative battery cable
  2.   Remove the charge air inlet hose.
  3.   Disconnect the fuel quantity solenoid wiring harness connector.
  4.   Remove the solenoid from the back of the high pressure pump. See Fig. 80.

NOTE: Inspect the fuel quantity solenoid and high pressure pump passage for contamination or corrosion. If contamination or corrosion is present replace the high pressure pump.

5. Inspect solenoid and pump for corrosion.

FUEL QUANTITY SOLENOID📷 1

1 - EGR AIR CONTROL VALVE 2 - GEAR SUPPLY PUMP 3 - FUEL QUANTITY SOLENOID

  1.   Review the high pressure fuel system warning. See WARNING.
  2.   Lubricate the fuel quantity solenoid and seal with clean diesel fuel.
  3.   Install the solenoid into the high pressure pump, hand tighten the fasteners. See Fig. 81.
  4.   Torque the solenoid fasteners to 10.8 N.m (96 in. lbs.).
  5.   Connect the wiring harness connector.
  6.   Install the charge air inlet hose.
  7.   Start engine, allow to warm, shut engine off and inspect for leaks.

PEDAL - ACCELERATOR

SYSTEM DIAGNOSIS📷 1

Operation

A leaking fuel injector can cause excessive preignition knock, poor engine performance, excessive black smoke in the exhaust, poor fuel economy and rough engine idle. If the fuel injector needle valve does not operate properly, the engine may misfire and produce low power.

The Fuel Injection System is controlled by the Engine Control Module (ECM). If the ECM senses a fault in a monitored fuel system circuit, the ECM will store a Diagnostic Trouble Code (DTC), which can retrieved with a Scan Tool. The On-Board Diagnostic functions of the ECM must be used to test the system when diagnosing mechanical or electrical problems with the Fuel Injection System. In addition to diagnosing electrical faults, the Scan Tool has the following functions to test the mechanical operation of the injectors:

Compression Test Fuel Correction Test Balance Test Kill Test

SENSOR-ACCELERATOR PEDAL POSITION