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Fuel System: Installation: Overview

Fig 1: SWIRL ACTUATOR
GC0039513Courtesy of DAIMLERCHRYSLER CORP.
1 - SWIRL ACTUATOR
2 - EGR COOLER
  1. Position the actuator (1) on the intake manifold and tighten fasteners to 12N.m (106 in. lbs.). See Fig 1.
    CAUTION: Care must be taken when connecting the actuator and rod assembly. Failure to do so will result in poor connections during assembly or intake manifold replacement.
  2. Carefully connect the relationship rod to the actuator. Do Not Force  .
  3. Install the intake manifold:

    For 3.7L, (Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - INSTALLATION)

    For 4.7L, (Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - INSTALLATION) .

    For 5.7L, (Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - INSTALLATION) .

  4. Fill the cooling system using the appropriate H.O.A.T. coolant.
  5. Start the engine, allow to warm, turn engine off and inspect for leaks.
    WARNING: (Refer to FUEL SYSTEM - 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.
  6. Install the engine cover.
  7. Install the strut tower support.


Fig 1: Accelerator Pedal Position (APP) Sensor
GC0039516Courtesy of DAIMLERCHRYSLER CORP.
1 - HARNESS CONNECTOR
2 - FASTENERS
3 - ACCELERATOR PEDAL ASSEMBLY
  1. Connect the accelerator pedal position sensor wiring harness connector (1) to the sensor. See Fig 1.
  2. Position the accelerator pedal assembly (3) and install the fasteners (2). See Fig 1.
  3. Install the drivers lower dash board close out panel.
  4. Connect the negative battery cable.


  1. Install camshaft position sensor and tighten bolt to 8 N.m (71 in.lbs.).
  2. Reconnect electrical connector.
  3. Install engine cover.
  4. Reconnect negative battery cable.


Fig 1: CRANKSHAFT POSITION SENSOR
GC0039518Courtesy of DAIMLERCHRYSLER CORP.
1 - HEAT SHIELD
2 - CRANKSHAFT POSITION SENSOR
  1. Clean the crankshaft sensor bore and install the sensor (2). See Fig 1. Tighten the bolt to 9 N.m (80 in. lbs.).
  2. Connect the engine harness connector.
  3. Install the heat shield (1). See Fig 1.
  4. Lower the vehicle.
  5. Connect the negative battery cable.


WARNING: (Refer to FUEL SYSTEM - 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: The installation of the pressure sensor must be performed out of vehicle so that the sensor can be tightened properly.
  1. Install the fuel rail pressure sensor and new seal. Tighten to 22 N.m (194 lbs. in.).
  2. Install the fuel rail.
  3. Connect rail sensor electrical connector.
  4. Connect negative battery cable.
  5. Start engine, allow to warm, turn engine off and inspect for leaks.
  6. Install engine cover.


Fig 1: MANIFOLD AIR FLOW SENSOR
GC0039520Courtesy of DAIMLERCHRYSLER CORP.
1 - WIRING HARNESS
2 - AIR INTAKE HOSE
3 - CLAMP
4 - MAF SENSOR
5 - AIR CLEANER HOUSING
  1. Position the MAF sensor (4) to air cleaner housing (5) and install the retaining screws. See Fig 1.
  2. Connect the air intake hose (2) to the MAF sensor and tighten clamp (3).
  3. Connect the MAF wiring harness connector (1).
  4. Connect negative battery cable.


Fig 1: BOOST PRESSURE SENSOR
GC0039522Courtesy of DAIMLERCHRYSLER CORP.
1 - AIR FLOW CONTROL VALVE
2 - BOOST PRESSURE SENSOR
3 - CHARGE AIR CROSS OVER TUBE
4 - EGR TUBE
  1. Position the boost pressure sensor onto the charge air cross over tube and install the fasteners. See Fig 1. Tighten the fasteners to 9 N.m (80 in. lbs.).
  2. Connect the sensor wiring harness connector.
  3. Connect the negative battery cable.


Fig 1: INTAKE AIR TEMPERATURE SENSOR
GC0039524Courtesy of DAIMLERCHRYSLER CORP.
1 - INTAKE AIR TEMPERATURE SENSOR
2 - AIR CONTROL VALVE
3 - AIR CONTROL VALVE EXTENTION
4 - LOWER CHARGE AIR HOSE
  1. Position the intake air temperature sensor along side of the air control valve extention (3) access hole.
  2. Press together the sensor (1) locking tabs, seat the sensor (1) to the extention (3) and release tabs. See Fig 1.
  3. Connect negative battery cable.


Fig 1: FUEL QUANTITY SOLENOID AND FUEL TEMPERATURE SENSOR
GC0039525Courtesy of DAIMLERCHRYSLER CORP.
1 - LOW PRESSURE FUEL SUPPLY
2 - RETURN FUEL
3 - HIGH PRESSURE SUPPLY TO FUEL RAIL
4 - FUEL TEMPERATURE SENSOR
5 - FUEL QUANTITY SOLENOID
6 - HIGH PRESSURE FUEL PUMP
  1. Clean sealing surfaces.
  2. Install new seal on sensor.
  3. Screw the sensor into the high pressure pump and tighten to 25 N.m (18 lbs.ft.). See Fig 1.
  4. Connect the temperature sensor wiring harness connector.
  5. Connect the fuel quantity solenoid wiring harness connector.
  6. Connect negative battery cable.
  7. Start engine, allow to warm, shut engine off and inspect for leaks.
    WARNING: (Refer to FUEL SYSTEM - 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.


WARNING: (Refer to Fuel System - 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: The fuel pressure solenoid is serviced with the left fuel rail only.


Fig 1: FUEL QUANTITY SOLENOID AND FUEL TEMPERATURE SENSOR
GC0039525Courtesy of DAIMLERCHRYSLER CORP.
1 - LOW PRESSURE FUEL SUPPLY
2 - RETURN FUEL
3 - HIGH PRESSURE SUPPLY TO FUEL RAIL
4 - FUEL TEMPERATURE SENSOR
5 - FUEL QUANTITY SOLENOID
6 - HIGH PRESSURE FUEL PUMP
  1. Clean sealing surfaces.
  2. Install new seal on sensor.
  3. Position the solenoid on to the high pressure pump and install fasteners. See Fig 1.
  4. Connect wiring harness connector to the solenoid.
  5. Connect negative battery cable.
  6. Start the engine, allow to run, turn engine off and inspect for leaks.
    WARNING: (Refer to FUEL SYSTEM - 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.


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: Assure fuel filter drain port is closed.
  1. Connect fuel heater electrical connector.
  2. Position fuel filter in bracket and tighten retaining bolt.
  3. Connect fuel feed and return lines.
  4. Connect negative battery cable.
  5. Start engine and inspect for leaks.


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 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 fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system.
Fig 1: HIGH PRESSURE PUMP REMOVAL/INSTALLATION
GC0039503Courtesy of DAIMLERCHRYSLER CORP.
  1. Install high pressure pump to the left cylinder head. Torque mounting bolts to 14 N.m (10 ft. lbs.).
  2. Connect the pump electrical connectors.
  3. Install fuel lines at pump.
    Fig 2: PUMP FUEL LINE PLIERS
    GC0039504Courtesy of DAIMLERCHRYSLER CORP.
  4. Install inlet supply line clamp using Fuel Line Pliers 9539.
  5. Install return line clamp using Fuel Line Pliers 9539.
    CAUTION: Do not crimp or bend fuel line. Inspect sealing cone at line; replace line if compression exists.
  6. Install high pressure fuel line retaining nuts. Torque nuts to 33 N.m (24 ft.lbs.).
  7. Install high pressure line support bracket.
  8. Install negative battery cable.
  9. Install the engine cover.
  10. Start engine and check for leaks.


NOTE: Remove any dirt and debris around the fuel filter assembly using a suitable solvent or compressed air. Area around the fuel filter assembly must be clean and dry.
  1. Lubricate the water in fuel (WIF) sensor O-rings with clean diesel fuel.
  2. Insert the WIF sensor into the fuel filter assembly and twist the sensor until the retaining holes align with the retaining bracket on the fuel filter assembly.
  3. Install the retaining screws. Tighten to 1.5 N.m (13 in. lbs.).
  4. Connect the WIF wiring harness connector.
  5. Connect the negative battery cable.
  6. Start the engine, allow to warm, turn engine off and inspect for leaks.
  7. Install engine cover.


Fig 1: FUEL LINE SEALING CONE
GC0039505Courtesy of DAIMLERCHRYSLER CORP.
1 - FUEL RAIL
2 - HIGH PRESSURE FUEL LINES
3 - HIGH PRESSURE LINE SEALING CONE
WARNING: (Refer to Fuel System - Warning) . No sparks, open flames or smoking. Risk of poisoning from inhaling and swallowing fuel. Risk of injury to eyes and skin from contact with fuel. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing.
  1. Loosen the fuel rail mounting bolts to install lines free of stress.
    CAUTION: Inspect sealing cone at lines. See Fig 1. Replace if compression points exist. Ensure lines are exactly located.
  2. Position and install fuel lines. Tighten to 22 N.m (195 lbs. in.).
  3. Tighten fuel rail to 14 N.m (124 lbs. in.).
  4. Install engine cover.
  5. Connect negative battery cable.
  6. Start engine, allow to warm, turn engine off and inspect for leaks.


Fig 1: Fuel Tank Mounting
GC0027829Courtesy of DAIMLERCHRYSLER CORP.
  1. If fuel tank is to be replaced, install fuel pump module into tank (Refer to FUEL SYSTEM/FUEL DELIVERY/FUEL PUMP MODULE - INSTALLATION) .
  2. Position fuel tank to hydraulic jack.
  3. Raise tank until positioned to body.
  4. Install and tighten bolts (1,2 and 3). See Figure. Refer to TORQUE  Specifications.
  5. Remove hydraulic jack.
    Fig 2: FUEL LINES - REAR
    GC0044900Courtesy of DAIMLERCHRYSLER CORP.
  6. Position rubber fill hose (2) to tank fitting (3). Tighten clamp (4). See Figure.
  7. Connect fuel vent connectors (1) and (5) at rear of tank (Refer to FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STANDARD PROCEDURE) .
    Fig 3: FUEL LINES - FRONT
    GC0044899Courtesy of DAIMLERCHRYSLER CORP.
  8. Connect fuel line connectors (1) and (2) at front of tank (3) See Figure.(Refer to FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STANDARD PROCEDURE) .
    Fig 4: FUEL PUMP MODULE PIGTAIL HARNESS
    GC0044898Courtesy of DAIMLERCHRYSLER CORP.
  9. Connect pump module electrical pigtail connector (1) to body wiring harness connector (2). See Figure.
  10. Lower vehicle.
  11. Fill fuel tank with fuel.
  12. Start engine and check for fuel leaks near top of pump module.


Fig 1: Fuel Pump Module Location
GC0010080Courtesy of DAIMLERCHRYSLER CORP.
CAUTION: Whenever the fuel pump module is serviced, the rubber seal (gasket) must be replaced.
  1. Using a new seal (gasket), position fuel pump module into opening in fuel tank.
  2. Position lockring (5) over top of fuel pump module. See Fig 1.
  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 fittings on top of pump module are pointed to right side of vehicle.
  4. Install Lockring Remover/Installer 9340 (3) to lockring.
  5. Install 1/2 inch drive breaker (1) into Lockring Remover/Installer 9340 (3).
  6. Tighten lockring (clockwise) until all seven notches have engaged.
    Fig 2: FUEL PUMP MODULE (TOP) - DIESEL
    GC0044901Courtesy of DAIMLERCHRYSLER CORP.
  7. Connect pigtail harness connector (2) to pump module (7). See Fig 2.
  8. Connect fittings (3) and (6) to pump module. (Refer to FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STANDARD PROCEDURE) 
  9. Install fuel tank. (Refer to FUEL SYSTEM/FUEL DELIVERY/FUEL TANK - INSTALLATION) 


Fig 1: Fuel Tank Mounting
GC0027829Courtesy of DAIMLERCHRYSLER CORP.
  1. Install fuel level sending unit onto module.
  2. If fuel tank is to be replaced, install fuel pump module into tank (Refer to FUEL SYSTEM/FUEL DELIVERY/FUEL PUMP MODULE - INSTALLATION) .
  3. Position fuel tank to hydraulic jack.
  4. Raise tank until positioned to body.
  5. Install and tighten bolts (1, 2, and 3). See Figure. Refer to TORQUE  Specifications.
  6. Remove hydraulic jack.
    Fig 2: FUEL LINES - REAR
    GC0044900Courtesy of DAIMLERCHRYSLER CORP.
  7. Position rubber fill hose (2) to tank fitting (3). Tighten clamp (4). See Figure.
  8. Connect fuel vent connectors (1) and (5) at rear of tank (Refer to FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STANDARD PROCEDURE) .
    Fig 3: FUEL LINES - FRONT
    GC0044899Courtesy of DAIMLERCHRYSLER CORP.
  9. Connect fuel line connectors (1) and (2) at front of tank (3) See Figure.(Refer to FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STANDARD PROCEDURE) .
    Fig 4: FUEL PUMP MODULE PIGTAIL HARNESS
    GC0044898Courtesy of DAIMLERCHRYSLER CORP.
  10. Connect pump module electrical pigtail connector (1) to body wiring harness connector (2). See Figure.
  11. Lower vehicle.
  12. Fill fuel tank with fuel.
  13. Start engine and check for fuel leaks near top of pump module.
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