High Pressure Fuel Pump Failure – 2021-2023 Jeep Wrangler, Gladiator, & 2022-2023 Ram 1500

Defect Notice 573 Report

RCLRPT-23V263-3671.PDF 216.019KB

Recall Acknowledgement

RCAK-23V263-5052.pdf 645.311KB

Manufacturer Notices(to Dealers,etc) – NSRAC re New Safety Recall Advanced Communication – 02A

RCMN-23V263-9600.pdf 48.984KB

SEOCONTENT-START

This notice applies to your vehicle,
01A/NHTSA 23V-263
YOUR SCHEDULING OPTIONS
1. Visit recalls.mopar.com to sign up for email or SMS notifications for when remedy parts become available. You will be asked to provide your Vehicle Identification Number (VIN), provided above
2. Scan below using your smartphone or tablet to sign up to be notified when remedy parts become available
3. Wait for FCA US to contact you again, by mail, with a follow-up recall notice when remedy parts are available
4. Call the FCA Recall Assistance Center at 1-800-853-1403. An agent can sign you up to be notified when remedy parts become available, or answer any other questions you may have
DEALERSHIP INSTRUCTIONS
Please reference Safety Recall 01A.
IMPORTANT SAFETY RECALL
High Pressure Fuel Pump
Dear [Name],
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.
FCA US LLC, has decided that a defect, which relates to motor vehicle safety, exists in certain [2022 through 2023 Model Year (DT) Ram 1500 Pickups and 2021 through 2023 Model Year (JL) Jeep® Wrangler and (JT) Gladiator] vehicles.
WHY DOES MY VEHICLE NEED REPAIRS?
The High Pressure Fuel Pump (HPFP) on your vehicle [1] may fail prematurely. A HPFP failure may introduce internally failed component debris into the fuel system potentially causing fuel starvation. Fuel starvation may result in an unexpected loss of motive power, which can cause a vehicle crash without prior warning.
HOW DO I RESOLVE THIS IMPORTANT SAFETY ISSUE?
The remedy for this condition is not currently available. We are making every effort to finalize the remedy, and will service your vehicle free of charge (parts and labor) when the remedy is available.
FCA US will contact you again, by mail, with a follow-up recall notice when the remedy is available. Once you receive your follow-up notice, simply contact your Chrysler, Jeep®, Dodge or RAM dealer right away to schedule a service appointment [2]. Additional options for your next steps are included on the left side of this notification. We appreciate your patience.
WHAT IF I ALREADY PAID TO HAVE THIS REPAIR COMPLETED?
If you have already experienced this specific condition and have paid to have it repaired, you may visit www.fcarecallreimbursement.com to submit your reimbursement request online [3]. Once we receive and verify the required documents, reimbursement will be sent to you within 60 days. If you have had previous repairs performed and/or already received reimbursement, you may still need to have the recall repair performed.
We apologize for any inconvenience, but are sincerely concerned about your safety. Thank you for your attention to this important matter.
Customer Assistance/Field Operations
FCA US LLC
[Model Year and Model]
VIN XXXXXXXXXXXXXXXXX
VEHICLE PICTURE
LOGO
QR Code
[1] If you no longer own this vehicle, please help us update our records. Call the FCA Recall Assistance Center at 1-800-853-1403 to update your information.
[2] If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National
Highway Traffic Safety Administration, 1200 New Jersey Ave., S.E., Washington, DC 20590, or you can call the toll-free Vehicle Safety Hotline at 1-888-327-4236
(TTY 1-800-424-9153), or go to safercar.gov.
[3] You can also mail in your original receipts and proof of payment to the following address for reimbursement consideration: FCA Customer Assistance, P.O. Box 21-
8004, Auburn Hills, MI 48321-8007, Attention: Recall Reimbursement.
Note to lessors receiving this recall notice: Federal regulation requires that you forward this recall notice to the lessee within 10 days.
Mr. Mrs. Customer
1234 Main Street
Hometown, MI 48371

**************************************************************************************************************

SAFETY RECALL – NORTH AMERICA
High Pressure Fuel Pump
Reference: 01A / NHTSA 23V-263
FCA US LLC
_________________________________________________________
Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any intervention.
Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer.
Reproduction forbidden without the written agreement of STELLANTIS Group. . (djt)
1/125
Remedy available for
2021-2023 JL Wrangler and JT Gladiator
Remedy available for
2022-2023 DT Ram 1500 Pickup
Template Version 1.8
Revision Edition Detail
4 April 2024 Related and Optional Equipment LOPs have been added.
SUBJECT
The High-Pressure Fuel Pump (HPFP) on about
49,900 of the above vehicles may fail prematurely. A
HPFP failure may introduce internally failed
component debris into the fuel system potentially
causing fuel starvation. Vehicle occupants may
notice a Malfunction Indicator Lamp, service
Electronic Throttle Control indicator, a fuel leak at the
HPFP, or excessive noise from the HPFP. Fuel
starvation may result in an unexpected loss of motive
power, which can cause vehicle crash without prior
warning.
SCOPE
This recall applies only to the above vehicles equipped
with a 3.0L engine (sales code EXH or EXJ).
NOTE: Some vehicles above may have been
identified as not involved in this recall and therefore
have been excluded from this recall.
IMPORTANT: Some of the involved vehicles may be
in dealer new vehicle inventory. Federal law requires
you to complete this recall service on these vehicles
before retail delivery. Dealers should also consider
this requirement to apply to used vehicle inventory and
should perform this recall on vehicles in for service.
Involved vehicles can be determined by using the VIP
inquiry process.
REPAIR TO BE PERFORMED
Vehicles delivered to the dealer in good running
condition should complete HPFP replacement
only(non-contaminated system).
If the vehicle is brought to the dealer not running, the
technician will follow the current diagnostic procedure
to determine if there was an HPFP failure. If HPFP
failure was determined, replacement of both the HPFP
and fuel pump module is required, including fuel
system cleaning (contaminated system).
ALTERNATE TRANSPORTATION
Dealers should attempt to minimize customer
inconvenience by placing the owner in a loaner vehicle
if inspection determines that complete fuel system
cleaning and replacement is required, and the vehicle
must be held overnight.
COMPLETION REPORTING AND
REIMBURSEMENT
Claims for vehicles that have been serviced must be
submitted on the DealerCONNECT Claim Entry
Screen located on the Service tab. Claims paid will
be used by FCA to record recall service completions
and provide dealer payments.
Use the following labor operation numbers and time
allowances:
SAFETY RECALL – NORTH AMERICA
High Pressure Fuel Pump
Reference: 01A / NHTSA 23V-263 FCA US LLC
_________________________________________________________
Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any intervention.
Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer.
Reproduction forbidden without the written agreement of STELLANTIS Group. (DJT)
2/125
Labor Description Number Hrs
Replace High Pressure Fuel
Pump (JL and JT Only)
14-01-A1-84 1.2
Replace High Pressure Fuel
Pump, Fuel Rails, Fuel Lines,
Fuel Injectors, Fuel Filter, In
Tank Fuel Pump, and Flush
Lines (JL and JT Only)
14-01-A1-85 5.0
Replace High Pressure Fuel
Pump (DT only)
14-01-A1-82 1.8
Replace High Pressure Fuel
Pump, Rails, Injectors, Filter,
In Tank Pump, and Flush
Lines (DT Only)
14-01-A1-83 6.5
Related Operations Number Hrs
Fuel Allowance to Safety
Recall 01A
95-14-01-50
Disposal of Contaminated
Diesel Fuel for Safety Recall
01A (Receipt Required)
95-14-04-51
Optional Equipment Number Hrs
Drain Fuel – DT Models w/ 26
Gallon Tank Only
14-01-A1-60 0.3
Drain Fuel – DT Models w/ 33
Gallon Tank Only
14-01-A1-61 0.4
Drain Fuel – JL Models w/
18.3 Gallon Tank Only
14-01-A1-62 0.3
Drain Fuel – JT Models w/ 19
Gallon Tank Only
14-01-A1-63 0.3
Labor Description Number Allowance
Floor Plan Reimbursement 95-95-95-97
Calculate
See Below
Floor Plan Reimbursement represents the vehicle’s
average daily allowance (see table below) multiplied
by the number of days the vehicle was in dealer
inventory and not available for sale. This
reimbursement is limited to the number of days from
the date of the stop sale to the date that the remedy
was made available. Note: If the vehicle was
received by your dealership (KZX date) AFTER the
stop sale date, you will use the KZX date instead of
the stop sale date. For this Recall, the stop sale was
initiated on 04/20/2023. The remedy for JL/JT was
made available on 10/03/2023, therefore, the number
of days cannot exceed 166 days. The remedy for DT
was made available on 10/31/2023, therefore, the
number of days cannot exceed 194 days.
Vehicle
Average Daily
Allowance
2021-2023 (JL) Jeep
Wrangler
2021-2023(JT) Jeep
Gladiator
2022-2023 DT Ram 1500
Pickup
Add the cost of the recall parts package plus
applicable dealer allowance to your claim.
In addition, enter “MATL” in the Part Number
section of your claim with the applicable Material
Allowance where appropriate.
NOTE: See the Warranty Administration Manual,
Recall Claim Processing Section, for complete
recall claim processing instructions.
PARTS INFORMATION
Part No. Qty. Part Name
JL/JT & DT PARTS
ORDER THESE PARTS FOR ALL VEHICLES
CSSMZ461AA 1 HP Fuel Pump (JL/JT/DT)
(Contaminated and Non-
Contaminated Vehicle)
CSGNZ961AA HP Fuel Pump Campaign Kit
(JL/JT/DT) (Contaminated
and Non-Contaminated
Vehicle)
1 EGR Tube (Gasket)
1 Rubber Gasket – Upper EGR
Tube
SAFETY RECALL – NORTH AMERICA
High Pressure Fuel Pump
Reference: 01A / NHTSA 23V-263
FCA US LLC
_________________________________________________________
Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any intervention.
Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer.
Reproduction forbidden without the written agreement of STELLANTIS Group. (DJT)
3/125
Part No. Qty. Part Name
04275086AE 1 Authorized Modification
Label (Contaminated and
Non-Contaminated Vehicle)
CSFP01A1AA SEE ORDERING
INFORMATION BELOW
THIS TABLE. (Contaminated
and Non-Contaminated
Vehicle)
1 Owner’s Manual Addendum
1 Tip Card
1 Fuel Door Decal
Process Steps to Order Campaign kit
CSFP01A1AA:
1. Access the “DealerCONNECT” website.
2. Select the “Marketing” link in the header of
DealerCONNECT.
3. Locate the “Product Information” section
heading on the Marketing page.
4. Select the “Literature and Merchandising
Materials” link in the product information
section.
5. Locate the “MOPAR” section heading on the
Literature and Merchandising Materials page.
6. Select the “Recall Labels / Cards” link listed
in the MOPAR section.
7. Select Item > Update Cart > Submit Order.
JL/JT PARTS
ALONG WITH THE PARTS ON PAGE 2, ORDER
THESE PARTS FOR NON-CONTIMATED JL/JT
VEHICLES (NO HPFP FAILURE)
CSGNZ965AA HPFP Campaign Kit (JL/JT)
(Non – Contaminated
vehicles only)
1 Tube – Fuel Feed to Pump
(Pump to Right Rail)
1 Tube – Fuel Feed to Pump
(Pump to Left Rail)
1 Tube – Fuel Injector Supply
JL/JT PARTS
ALONG WITH THE PARTS ON PAGE 2, ORDER
THESE PARTS FOR CONTAMINATED JL/JT
VEHICLES (WITH HPFP FAILURE)
CSGNZ966AA Fuel Pump & Level Unit
(JL/JT) (Contaminated
vehicles only)
1 Fuel Pump and Level Unit
(O-Ring)
1 Fuel Pump/Level Unit (Pkg
Part)
68490022AA 6 Fuel Injector (JL/JT)
(Contaminated vehicles only)
68148333AA 6 Seal – Fuel Injector (JL/JT)
(Contaminated vehicles only)
68148329AB 1 Fuel Rail – Right (JL/JT)
(Contaminated vehicles only)
68490028AA 1 Fuel Rail – Left (JL/JT)
(Contaminated vehicles only)
SAFETY RECALL – NORTH AMERICA
High Pressure Fuel Pump
Reference: 01A / NHTSA 23V-263
FCA US LLC
_________________________________________________________
Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any intervention.
Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer.
Reproduction forbidden without the written agreement of STELLANTIS Group. (DJT)
4/125
68436631AA 1 Filter Kit (Fuel Water
Separator) (JL/JT)
(Contaminated vehicles only)
68493361AA 1 O-Ring (Upper Turbo Inlet
Elbow/EGR Cooler Elbow to
LP EGR Valve) (JL/JT)
(Contaminated vehicles only)
68487031AA 1 O-Ring (Turbo Upper Air
Intake Elbow/EGR Cooler
Elbow to Turbo Air Intake
Elbow) (JL/JT)
(Contaminated vehicles only)
68524869AA 1 TUBE KIT – FUEL SUPPLY
(6 Tubes injector to rail, 2
tubes rail to pump, 1 tube rail
to rail) (JL/JT)
(Contaminated vehicles only)
DT PARTS
ALONG WITH THE PARTS ON PAGE 2, ORDER
THESE PARTS FOR NON-CONTIMATED DT
VEHICLES (NO HPFP FAILURE)
CSGNZ963AA HPFP Campaign Kit (DT)
(Non – Contaminated
vehicles only)
1 Fuel Feed to Pump (Pump to
Left Rail)
1 Fuel Feed to Pump (Pump to
Right Rail)
4 NUT – Injection Pump Cover
1 Tube – Fuel Injector Supply
1 Tube – Fuel Injector Supply
DT PARTS
ALONG WITH THE PARTS ON PAGE 2, ORDER
THESE PARTS FOR CONTAMINATED DT
VEHICLES (WITH HPFP FAILURE)
CSGNZ964AA HPFP Campaign Kit (DT)
(Contaminated vehicles only)
1 Tube Kit – Fuel Supply (6
Tubes injector to rail, 2 tubes
rail to pump, 1 tube rail to
rail)
1 Fuel Pump and Level Unit
(O-Ring)
1 Fuel Pump/Level Unit (Pkg
Part)
68490022AA 6 Fuel Injector (DT)
(Contaminated vehicles only)
68148333AA 6 Seal – Fuel Injector (DT)
(Contaminated vehicles only)
68148329AB 1 Fuel Rail – Right (DT)
(Contaminated vehicles only)
SAFETY RECALL – NORTH AMERICA
High Pressure Fuel Pump
Reference: 01A / NHTSA 23V-263
FCA US LLC
_________________________________________________________
Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any intervention.
Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer.
Reproduction forbidden without the written agreement of STELLANTIS Group. (DJT)
5/125
68490028AA 1 Fuel Rail – Left (DT)
(Contaminated vehicles only)
68436631AA 1 Filter Kit (Fuel Water
Separator) (DT)
(Contaminated vehicles only)
68493361AA 1 O-Ring (Upper Turbo Inlet
Elbow/EGR Cooler Elbow to
LP EGR Valve) (DT)
(Contaminated vehicles only)
68487031AA 1 O-Ring (Turbo Upper Air
Intake Elbow/EGR Cooler
Elbow to Turbo Air Intake
Elbow) (DT) (Contaminated
vehicles only)
SAFETY RECALL – NORTH AMERICA
High Pressure Fuel Pump
Reference: 01A / NHTSA 23V-263
FCA US LLC
_________________________________________________________
Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any intervention.
Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer.
Reproduction forbidden without the written agreement of STELLANTIS Group. (DJT)
6/125
PARTS RETURN
No parts return required for this campaign.
SPECIAL TOOLS
Number Description Picture
NPN wiTECH MicroPod II
NPN Laptop Computer
NPN wiTECH Software
VM.10345
Tool, High Pressure Pump
Installation
1023
Puller (Originally Shipped In
Kit Number(s) 8678)
APS35IB
Blue Point Spanner Wrench
or equivalent
202540009
0
Remover-Installer, Fuel Rail
Bolt
VM.10358A Remover, Fuel Injector
9717
Brush, Injector Bore
(Originally Shipped In Kit
Number(s) 9910)
8978A Decay Tool, Fuel
9340
SAE Fuel Pump Lock Ring
Wrench (Originally
Shipped In Kit Number(s)
9327, 9327CC, 9397,
9575.
DEALER NOTIFICATION
To view this notification on DealerCONNECT, select
“Global Recall System” on the Service tab, then click
on the description of this notification.
OWNER NOTIFICATION AND SERVICE
SCHEDULING
All involved vehicle owners known to FCA are being
notified of the service requirement by first class mail.
They are requested to schedule appointments for this
service with their dealers. A generic copy of the owner
letter is attached.
VEHICLE LISTS, GLOBAL RECALL SYSTEM, VIP
AND DEALER FOLLOW UP
All involved vehicles have been entered into the
DealerCONNECT Global Recall System (GRS) and
Vehicle Information Plus (VIP) for dealer inquiry as
needed.
GRS provides involved dealers with an updated VIN
list of their incomplete vehicles. The owner’s name,
address and phone number are listed if known.
Completed vehicles are removed from GRS within
several days of repair claim submission.
To use this system, click on the “Service” tab and then
click on “Global Recall System.” Your dealer’s VIN
list for each recall displayed can be sorted by: those
vehicles that were unsold at recall launch, those with
a phone number, city, zip code, or VIN sequence.
Dealers must perform this repair on all unsold
vehicles before retail delivery. Dealers should also
use the VIN list to follow up with all owners to schedule
appointments for this repair.
Recall VIN lists may contain confidential, restricted
owner name and address information that was
obtained from the Department of Motor Vehicles of
various states. Use of this information is permitted for
this recall only and is strictly prohibited from all other
use.
ADDITIONAL INFORMATION
If you have any questions or need assistance in
completing this action, please contact your Service
and Parts District Manager.
Customer Services / Field Operations
FCA US LLC.
SAFETY RECALL – NORTH AMERICA
High Pressure Fuel Pump
Reference: 01A / NHTSA 23V-263
FCA US LLC
_________________________________________________________
Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any intervention.
Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer.
Reproduction forbidden without the written agreement of STELLANTIS Group. (DJT)
7/125
SERVICE PROCEDURE
For vehicles with a contaminated fuel system, use the procedure below.
A. DT Vehicles
Replace
WARNING: High-pressure lines deliver diesel fuel under extreme pressure from the injection pump to
the fuel injectors. This may be as high as 2000 bar (29,008 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.
WARNING: Observe the following precautions when working on fuel systems: No sparks, open flames
or smoking. Avoid inhaling and swallowing fuel. Avoid eye and skin contact with fuel. Pour fuels only
into suitable and appropriately marked containers. Wear protective clothing. Failure to observe these
precautions may result in fire, explosion, property damage, and serious or fatal injury.
WARNING: High-pressure lines deliver diesel fuel under extreme pressure from the injection pump to
the fuel injectors. This may be as high as 2000 bar (29,008 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.
WARNING: Observe the following precautions when working on fuel systems: 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: When key is cycled to the off position, fuel system pressure automatically bleeds down.
NOTE: The fuel injection pump can be replaced without having to perform the entire base engine valve
timing procedure. This procedure gives instruction on how to remove and install the new fuel injection
pump without performing the base engine timing. Do not rotate the pump shaft after removing from the
vehicle. The alignment of the pump shaft must be measured and recorded using a commercially
available degree wheel after the pump is removed and before transferring the pump gear over to the
new pump. This is done to align the pump to the same position during installation. If the base engine
valve timing must be performed as part of the repair, refer to Service Library 09 – Engine/Valve
Timing/Standard Procedure.
SAFETY RECALL – NORTH AMERICA
High Pressure Fuel Pump
Reference: 01A / NHTSA 23V-263
FCA US LLC
_________________________________________________________
Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any intervention.
Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer.
Reproduction forbidden without the written agreement of STELLANTIS Group. (DJT)
8/125
1. Remove and isolate the negative battery cable
eyelet from the IBS. This will isolate the 12 volt
from the vehicle electrical system (Figure 1).
NOTE: If removing the negative battery cable
clamp from the battery post instead of removing
the negative battery cable eyelet, the Intelligent
Battery Sensor (IBS) wire harness connector must
be disconnecting prior to removing the cable end.
Failure to disconnect the IBS wire harness
connector can lead to damage of the IBS wire
harness connector.
2. Disconnect the negative battery cable by
removing the ground terminal nut (1) (Figure 1).
3. Remove the two bolts (1) securing the engine
cover (2) (Figure 2).
4. Lift up and pull forward and remove the engine
cover (2) (Figure 2).
Figure 1 – Battery Disconnect
Figure 2 – Engine Cover
SAFETY RECALL – NORTH AMERICA
High Pressure Fuel Pump
Reference: 01A / NHTSA 23V-263
FCA US LLC
_________________________________________________________
Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any intervention.
Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer.
Reproduction forbidden without the written agreement of STELLANTIS Group. (DJT)
9/125
5. Loosen the clamp (1) and disconnect the clean air
hose (Figure 3).
6. Detach the coolant hose retainer (2) from the
clean air hose (Figure 3).
7. Remove the bolt (3) securing the clean air hose
(Figure 3).
8. Disconnect the Closed Crankcase Heater
Ventilation (CCV) heater wire harness connector
(1) (Figure 4).
9. Detach the CCV heater wire harness retainer (2)
(Figure 4).
10. Disconnect the crankcase breather hose (3)
(Figure 4).
Figure 3 – Clean Air Hose
Figure 4 – Closed Crankcase
Ventilation Connector
SAFETY RECALL – NORTH AMERICA
High Pressure Fuel Pump
Reference: 01A / NHTSA 23V-263
FCA US LLC
_________________________________________________________
Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any intervention.
Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer.
Reproduction forbidden without the written agreement of STELLANTIS Group. (DJT)
10/125
11. Loosen clamp (1) and remove the clean air hose
(2) (Figure 5).
12. Remove the fastener (1) securing the right Charge
Air Cooler (CAC) hose (Figure 6).
13. Release the retaining lock and disconnect the
right CAC hose (2) from the turbocharger
(Figure 6).
Figure 5 – Clean Air Hose
Figure 6 – CAC Hose
SAFETY RECALL – NORTH AMERICA
High Pressure Fuel Pump
Reference: 01A / NHTSA 23V-263
FCA US LLC
_________________________________________________________
Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any intervention.
Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer.
Reproduction forbidden without the written agreement of STELLANTIS Group. (DJT)
11/125
14. Remove the retainers (1) that secure the cover (2)
for the high-pressure fuel pump (Figure 7).
15. Remove the bolts (1) securing the sound proofing
(2) to the fuel injection pump (Figure 8).
Figure 7 – Pump Cover
Figure 8 – Pump Sound Proofing
SAFETY RECALL – NORTH AMERICA
High Pressure Fuel Pump
Reference: 01A / NHTSA 23V-263
FCA US LLC
_________________________________________________________
Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any intervention.
Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer.
Reproduction forbidden without the written agreement of STELLANTIS Group. (DJT)
12/125
16. Disconnect the fuel injection pump wire harness
connector (2) (Figure 9).
17. Remove the vent hose (1) from the left fuel rail
cover (Figure 10).
Figure 9 – Pump Connections
Figure 10 – Left Bank Fuel Rail Cover
SAFETY RECALL – NORTH AMERICA
High Pressure Fuel Pump
Reference: 01A / NHTSA 23V-263
FCA US LLC
_________________________________________________________
Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any intervention.
Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer.
Reproduction forbidden without the written agreement of STELLANTIS Group. (DJT)
13/125
18. Remove the bolts (2) and the left fuel rail cover (1)
(Figure 11).
19. Remove the fuel line supply safety clip (1)
(Figure 12).
Figure 11 – Left Bank Fuel Rail Cover
Bolts
Figure 12 – Safety Clip
SAFETY RECALL – NORTH AMERICA
High Pressure Fuel Pump
Reference: 01A / NHTSA 23V-263
FCA US LLC
_________________________________________________________
Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any intervention.
Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer.
Reproduction forbidden without the written agreement of STELLANTIS Group. (DJT)
14/125
20. Disconnect the fuel supply (2) and return (1) lines
(Figure 13).
21. Disconnect the fuel return lines (1, 2) (Figure 14).
22. Remove the fuel supply line bolt (3) and return line
bolt (4) and both lines (Figure 14).
23. Disconnect the low-pressure fuel supply and return lines (3) (Figure 9).
24. Remove the fuel rail supply tubes (1, 4) (Figure 9).
Figure 13 – Fuel Supply and Return
Lines
Figure 14 – Fuel Return Lines
SAFETY RECALL – NORTH AMERICA
High Pressure Fuel Pump
Reference: 01A / NHTSA 23V-263
FCA US LLC
_________________________________________________________
Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any intervention.
Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer.
Reproduction forbidden without the written agreement of STELLANTIS Group. (DJT)
15/125
25. Loosen the nut (1) and remove the right fuel rail
cover (2) (Figure 15).
Figure 15 – Right Fuel Rail Cover
SAFETY RECALL – NORTH AMERICA
High Pressure Fuel Pump
Reference: 01A / NHTSA 23V-263
FCA US LLC
_________________________________________________________
Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any intervention.
Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer.
Reproduction forbidden without the written agreement of STELLANTIS Group. (DJT)
16/125
26. Remove the left side bolts (1) from the upper High
Pressure (HP) Exhaust Gas Recirculation (EGR)
tube (2) (Figure 16).
27. Remove the right-side bolts (3) and the upper HP
EGR tube (2) (Figure 16).
28. Remove and discard both gaskets.
29. Remove the bolts, nuts and CAC hose support
bracket.
30. Remove the wire harness retainer (1) from the
right front of cylinder head cover (Figure 17).
Figure 16 – Upper High Pressure EGR
Tube
Figure 17 – Harness Retainer
SAFETY RECALL – NORTH AMERICA
High Pressure Fuel Pump
Reference: 01A / NHTSA 23V-263
FCA US LLC
_________________________________________________________
Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any intervention.
Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer.
Reproduction forbidden without the written agreement of STELLANTIS Group. (DJT)
17/125
31. Lift up on the locking retaining tab (1) to unlock
the lock (Figure 18).
32. Disconnect the fuel return line (2) by wiggling the
hose free from the fuel injector (Figure 18).
NOTE: Use a backing wrench on the fuel
injector when unscrewing the union nut.
33. Unscrew the union nuts (7 and 9) and remove
cylinder No. 1 fuel tube (8) and the discard fuel
tube (Figure 19).
34. Install protective caps to the fuel injector and fuel
rail for cylinder No. 1 (Figure 19).
35. Unscrew the union nuts (4, 6) and remove cylinder
No. 2 fuel tube (5), and discard the fuel tube
(Figure 19).
36. Install protective caps to the fuel injector and fuel
rail for cylinder No. 2 (Figure 19).
37. Unscrew the union nuts (1, 3) and remove cylinder
No. 3 fuel tube (2), and discard the fuel tube
(Figure 19).
38. Install protective caps to the fuel injector and fuel
rail for cylinder No. 3 (Figure 19).
Figure 18 – Fuel Return Lines and
Locking Tabs
Figure 19 – Right Bank Fuel Pipes
SAFETY RECALL – NORTH AMERICA
High Pressure Fuel Pump
Reference: 01A / NHTSA 23V-263
FCA US LLC
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39. Unscrew the union nuts (1, 3) and remove and
discard the fuel tube (2) (Figure 20).
40. Remove the PCV pipe from the valve cover.
41. Remove the right high pressure fuel line that
connects the pump to the rail.
42. Detach the retainers (1) securing the fuel return
hose to the fuel line support bracket (Figure 21).
Figure 20 – Right Bank Fuel Supply
Tube
Figure 21 – Fuel Return Hose Retainers
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High Pressure Fuel Pump
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FCA US LLC
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43. Detach the wire harness retainer (3) (Figure 22).
44. Remove the bolts (1) fuel line support bracket (2)
(Figure 22).
45. Remove the bolt (1) securing the fuel tube (Figure
23).
Figure 22 – Harness Retainer
Figure 23 – Fuel Tube Bolt
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High Pressure Fuel Pump
Reference: 01A / NHTSA 23V-263
FCA US LLC
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46. Unscrew the union nut (2) and remove the fuel
tube (1) and then discard the fuel tube
(Figure 24).
47. Lift up on the locking retaining tab (1) to unlock
the lock (Figure 25).
48. Disconnect the fuel return line (2) by wiggling the
hose free from the fuel injector (Figure 25).
NOTE: Use a backing wrench on the fuel
injector when unscrewing the union nut.
Figure 24 – Fuel Tube
Figure 25 – Fuel Return Lines and
Locking Tabs
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High Pressure Fuel Pump
Reference: 01A / NHTSA 23V-263
FCA US LLC
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49. Unscrew the union nuts (1 and 3) and remove
cylinder No. 4 fuel tubes (2) and discard the fuel
tubes (Figure 26).
50. Install protective caps onto the fuel injectors and
fuel rail.
51. Unscrew the union nuts (4, 6) and remove cylinder
No. 5 fuel tube (5), and discard the fuel tube
(Figure 26).
52. Install protective caps onto the fuel injectors and
fuel rail.
53. Unscrew the union nuts (7, 9) and remove cylinder
No. 5 fuel tube (8), and discard the fuel tube
(Figure 26).
54. Install protective caps onto the fuel injectors and
fuel rail.
CROSS-OVER FUEL TUBE
55. Remove the bolt (2) and reposition the differential
pressure sensor (1) away from the upper
turbocharger inlet elbow (Figure 27).
Figure 26 – Right Bank Fuel Pipes
Figure 27 – Differential Pressure
Sensor
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56. Remove and bolts (2) securing the low pressure
EGR valve to the upper turbocharger inlet elbow
(1) (Figure 28).
57. Remove the differential pressure sensor hose (2)
from the upper turbocharger inlet elbow and
remove the upper turbocharger inlet elbow (1)
from the lower turbocharger inlet elbow
(Figure 29).
Figure 28 – Low Pressure EGR Valve
Figure 29 – Differential Pressure
Sensor Hose
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58. Remove and DISCARD the low pressure EGR
valve gasket (1) (Figure 30).
59. Remove and DISCARD the lower turbocharger
inlet elbow gasket (1) (Figure 31).
Figure 30 – Low Pressure EGR Valve
Gasket
Figure 31 – Lower Turbocharger Inlet
Elbow Gasket
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60. Disconnect the boost pressure sensor wire
harness connector (1) (Figure 32).
61. Disconnect cylinder No. 3 glow plug wire
harness connector.
62. Disconnect the fuel rail pressure sensor wire
connector.
63. Disconnect the right-side rear swirl valve wire
harness connector.
64. Remove the bolt (1) securing the fuel crossover
tube (Figure 33).
Figure 32 – Sensor Harness Connector
Figure 33 – Crossover Tube Bolt
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65. Unscrew the union nuts (1, 3) and remove the
fuel crossover tube (2) and discard (Figure 34).
FUEL RAILS – Remove
66. Using the Remover-Installer, Fuel Rail Bolt
2025400090 remove the bolts (1) and the right
fuel rail (2) (Figure 35).
Figure 34 – Crossover Tube
Figure 35 – Right Fuel Rail Bolts
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67. Using the Remover-Installer, Fuel Rail Bolt
2025400090, remove the bolts (1) and the left
fuel rail (2) and discard (Figure 36).
68. Disconnect the fuel injection pump electrical
connector (2) (Figure 37).
69. Disconnect the low-pressure fuel supply and
return lines (3) (Figure 37).
NOTE: Use a backing wrench on the fuel
injector when unscrewing the union nut.
70. Unscrew the union nuts for the fuel rail supply
tubes (1 and 4) (Figure 37).
71. Disconnect the fuel quantity solenoid wire
harness connector (2) (Figure 37).
Figure 36 – Left Fuel Rail Bolts
Figure 37 – HPFP Electrical Connector
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High Pressure Fuel Pump
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NOTE: The fuel injection pump can be replaced without having to perform the entire base engine
valve timing procedure. Do not rotate the pump shaft after removing from the vehicle. The
alignment of the pump shaft must be measured and recorded using a commercially available
degree wheel after the pump is removed and before transferring the pump gear over to the new
pump. This is done to align the pump to the same position during installation. If the base engine
valve timing must be performed as part of the repair (Refer to 09 – Engine/Valve Timing/Standard
Procedure).
72. Remove the upper bolts (1) from the highpressure
pump (2) (Figure 38).
73. Using Tool, High Pressure Pump Installation
VM.10345 Install the studs in the upper
locations.
74. Remove the lower bolt (1) from the HPFP (2)
and remove it from the vehicle (Figure 39).
NOTE: The fuel injection pump needs to be
timed using a commercially available degree
wheel.
Figure 38 – Fuel Quantity Solenoid
Connector and HPFP Upper Bolts
Figure 39 – HPFP Lower Bolt
SAFETY RECALL – NORTH AMERICA
High Pressure Fuel Pump
Reference: 01A / NHTSA 23V-263
FCA US LLC
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75. Install the degree wheel onto the pump and
record the position of the hole in the gear on the
degree wheel (Figure 40).
76. The use of Puller 1023 or a commercially
available gear puller is required to remove the
fuel injection pump gear (Figure 41).
NOTE: The use of Puller 1023 or a
commercially available gear puller is required
to remove the fuel injection pump gear (2)
(Figure 41).
CAUTION: Do Not Force the high-pressure
pump into the right timing cover or attempt to
seat it by drawing it in with the bolts. The
pump gear must be properly aligned with the
drive gear on the camshaft before the highpressure
pump will seat on the cylinder head
mounting surface. Failure to properly align
drive gears will damage the high-pressure
pump or camshaft drive gear.
Figure 40 – Degree Wheel
Figure 41 – Gear Removal
SAFETY RECALL – NORTH AMERICA
High Pressure Fuel Pump
Reference: 01A / NHTSA 23V-263
FCA US LLC
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77. Install a NEW O-ring seal (1) to the fuel injection
pump (Figure 42).
78. Install the gear (2) and nut (1) onto the fuel
injection pump (3) and tighten the nut (1) finger
tight (Figure 43).
Note: NEVER use an impact to tighten the gear
nut.
Figure 42 – O-ring Seal
Figure 43 – O-ring Seal
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High Pressure Fuel Pump
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FCA US LLC
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79. Using a commercially available spanner wrench
(2) such as Blue Point APS35IB or equivalent,
tighten the nut (1) to 50 N·m (37 ft.
lbs.) (Figure 44).
80. Install the degree wheel and rotate the pump
shaft so that the hole aligns with the reference
mark on the degree wheel referenced during the
removal (Figure 45).
81. Install the fuel injection pump onto the Tool,
High Pressure Pump Installation VM.10345 in
the upper timing cover.
82. Install the lower fuel injection pump bolt (2) and
hand tighten the bolt (1) (Figure 39).
83. Remove the Tool, High Pressure Pump
Installation VM.10345 from the upper bolts
location and install the bolts.
84. Tighten the bolts (1) that secure the fuel
injection pump to 25 N·m (18 ft. lbs.) (Figures 38
and 39).
85. Connect the fuel injection pump electrical connector (2) (Figure 37).
Figure 44 – Nut with Spanner Wrench
Figure 45 – Degree Wheel
SAFETY RECALL – NORTH AMERICA
High Pressure Fuel Pump
Reference: 01A / NHTSA 23V-263
FCA US LLC
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WARNING: Observe the following precautions when working on fuel systems: No sparks, open
flames or smoking. Avoid inhaling and swallowing fuel. Avoid eye and skin contact with fuel. Pour
fuels only into suitable and appropriately marked containers. Wear protective clothing. Failure to
observe these precautions may result in fire, explosion, property damage, and serious or fatal
injury.
WARNING: High-pressure lines deliver diesel fuel under extreme pressure from the injection pump
to the fuel injectors. This may be as high as 2000 bar (29,008 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.
NOTE: High pressure fuel tubes are a one time only use and must be replaced anytime they have
been removed.
FUEL INJECTORS – Remove and Replace
86. Clean the area around the fuel injector to be
removed so that no debris falls into the injector
bore.
87. Remove the bolt (1) and the fuel injector clamp
(2) (Figure 46).
Figure 46 – Fuel Injector Bolt and
Clamp
SAFETY RECALL – NORTH AMERICA
High Pressure Fuel Pump
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FCA US LLC
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88. Using your hand, pull the fuel injector (1)
straight up from the cylinder head for removal.
Discard the lower sealing washer and place a
protective cap over the nozzle and injector
bore (Figure 47).
89. If injector can’t be removed by hand, install the
Remover, Fuel Injector VM.10358A (1) to
remove the fuel injector. Discard the injector.
Place a protective cap over the injector bore
(Figure 48).
NOTE: Check and MAKE SURE that the copper
sealing washer did not remain in the cylinder
head.
Figure 47 – Fuel Injector Bolt
Figure 48 – Fuel Injector Remover
SAFETY RECALL – NORTH AMERICA
High Pressure Fuel Pump
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FCA US LLC
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90. To remove the rear injector on the right side of
the engine, remove the EGR Cooler Vacuum
Bypass. Remove the E-clip from shaft on the
cooler, and two T25 Torx screws. Set the
bypass aside with heat shield and bracket
(Figure 49).
NOTE: When a NEW fuel injector is being installed, or if an existing injector is installed in any location
other than its original location, the injector quantity adjustment procedure must be performed (Refer to
14 – Fuel System/Fuel Injection – Standard Procedure).
91. Remove the protective cap from the appropriate injector bore.
NOTE: Make sure the old copper sealing washer is not stuck in bore.
92. Clean the fuel injector bore (Refer to 09 – Engine/Fuel Injection/INJECTORS, Fuel/Cleaning).
Figure 49 – EGR Cooler Bypass
E-CLIP
SCREWS
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High Pressure Fuel Pump
Reference: 01A / NHTSA 23V-263
FCA US LLC
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93. Install a NEW fuel injector seal (1) in the
cylinder head cover (Figure 50).
94. Install a NEW sealing washer (2) onto the fuel
injector (1) (Figure 51).
NOTE: Do Not apply any lubricant to the fuel
injector nozzle. Care must be taken not to restrict
the discharge orifices in the nozzle.
Figure 50 – Upper Sealing Washer
Figure 51 – Lower Sealing Washer
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High Pressure Fuel Pump
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95. Lubricate the injector body with Nickel Anti-
Seize Lubricant (Figure 52).
96. Install the fuel injector (1) in the cylinder head
(Figure 53).
Figure 52 – Lubricate the Fuel Injector
Figure 53 – Fuel Injector Bolt
SAFETY RECALL – NORTH AMERICA
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97. Install the fuel injector clamp (2) and tighten the
bolt (1) and tighten the bolt (1) to 33 N·m (24 ft.
lbs.) (Figure 54).
LEFT BANK – INSTALL
NOTE: Fuel tubes are a one-time only use and
must be replaced anytime they have been
removed.
NOTE: Transfer pipe clamps and dampers from
the old lines to the new as necessary.
98. Install the fuel rails. Using the Remover-Installer, Fuel Rail Bolt 2025400090 tighten the bolts to 25 N·m
(18 ft. lbs.).
99. Install the NEW right high-pressure fuel tube (2)
and tighten the union nuts (1, 3) to 11 N·m + 75°
(8 ft. lbs. + 75°) (Figure 55).
Figure 54 – Fuel Injector Bolt and
Clamp
Figure 55 – Right High-Pressure Fuel
Tube
SAFETY RECALL – NORTH AMERICA
High Pressure Fuel Pump
Reference: 01A / NHTSA 23V-263
FCA US LLC
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100. Install the nut (1) securing the high-pressure fuel
tube and tighten to 11 N·m (8 ft. lbs.)
(Figure 56).
NOTE: Use a backing wrench on the fuel injector when tightening the union nut.
NOTE: Do not use any type of lubrication when installing the fuel injector return line.
101. Install a NEW fuel crossover tube (2) and
tighten the union nuts (1, 3) to 11 N·m + 75° (8
ft. lbs. + 75°) (Figure 57).
Figure 57 – Crossover Tube
Figure 56 – High Pressure Fuel Tube
Bolt
SAFETY RECALL – NORTH AMERICA
High Pressure Fuel Pump
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102. Install the bolt (1) securing the fuel crossover
tube and tighten to 11 N·m (8 ft. lbs.)
(Figure 58).
103. Install the fuel supply tubes and tighten the fuel
tube union nuts to:
• At fuel injector, tighten to 11 N·m + 75° (8 ft.
lbs. + 75°).
• At fuel rail, tighten to 11 N·m + 75° (8 ft. lbs.
+ 75°).
104. Install the wire harness bracket (1) and securely
tighten the bolts (2) (Figure 59).
105. Connect the right-side rear swirl valve wire
harness connector.
106. Connect the fuel rail pressure sensor wire
connector.
107. Connect cylinder No. 3 glow plug wire harness
connector.
Figure 58 – Crossover Tube Bolt
Figure 59 – Harness Bracket Bolts
SAFETY RECALL – NORTH AMERICA
High Pressure Fuel Pump
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108. Connect the boost pressure sensor wire
harness connector (1) (Figure 60).
109. Install the turbocharger outlet elbow and
securely tighten the screws.
110. Using a NEW gasket, install the turbocharger
outlet elbow (2) and securely tighten the screws
(1) (Figure 61).
Figure 60 – Sensor Connector
Figure 61 – Turbo Outlet Elbow
SAFETY RECALL – NORTH AMERICA
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111. Connect the outlet air temperature sensor wire
harness connector (1) (Figure 62).
112. Install the fuel injector return line (2) and be sure
it is fully seated (Figure 63).
113. Push down on the lock tab (1) to lock in place
(Figure 63).
Figure 63 – Fuel Return Lines and
Locking Tabs
Figure 62 – Sensor Wire Harness
Connector
SAFETY RECALL – NORTH AMERICA
High Pressure Fuel Pump
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114. Install the left fuel rail cover (1) and securely
tighten the bolts (2) (Figure 64).
115. Install the vent hose to the left fuel rail cover (1)
(Figure 65).
Figure 64 – Left Bank Fuel Rail Cover
Bolts
Figure 65 – Left Bank Fuel Rail Cover
SAFETY RECALL – NORTH AMERICA
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116. Install the NEW left high pressure fuel tube (1)
and tighten the rail union nut (2) finger tight
(Figure 66).
117. Tighten the pump union nut (2) finger tight
(Figure 67).
118. Tighten both the union nuts to 11 N·m + 75° (8
ft. lbs. + 75°).
Figure 66 – Fuel Tube
Figure 67 – Fuel Tube
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119. Install the bolt (1) securing the high-pressure
fuel tube and tighten to 11 N·m (8 ft. lbs.)
(Figure 68).
120. Install the fuel line support bracket (2) and
tighten the bolts (1) to 11 N·m (8 ft. lbs.)
(Figure 69).
Figure 68 – Fuel Tube Bolt
Figure 69 – Harness Retainer
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121. Attach the retainers (1) securing the fuel return
hose to the fuel line support bracket (Figure 70).
122. Install the fuel return lines (1, 2) (Figure 71).
123. Install the fuel supply line and return line and
tighten the bolt (3, 4) to 11 N·m (8 ft. lbs.).
Figure 70 – Hose Retainers
Figure 71 – Fuel Return Lines
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124. Connect the fuel supply (2) and return (1) lines
(Figure 72).
125. Install the fuel line supply safety clip (1)
(Figure 73).
Figure 72 – Fuel Supply and Return
Lines
Figure 73 – Safety Clip
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126. Connect the low-pressure return (1) line to the
fuel injection pump. Leave the supply (2) loose
at this time (Figure 74).
127. Install the clean air hose (2) to turbocharger and
securely the tighten clamp (1) (Figure 75).
Figure 74 – Low Pressure Supply Lines
Figure 75 – Clean Air Hose
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128. Connect the crankcase breather hose.
129. Attach the Closed Crankcase Heater Ventilation
(CCV) heater wire harness retainer (2)
(Figure 76).
130. Connect the CCV hose heater wire harness
connector (1) (Figure 76).
FUEL TANK – DRAIN, CLEAN, REPLACE PUMP
Conventional Procedure
CAUTION: Dispose of petroleum based products in a manner consistent with all applicable Local,
State, Federal, and Provincial regulations.
NOTE: Due to a one-way check valve installed into the fuel fill fitting at the tank, the tank cannot be
drained at the fuel fill cap.
131. Disconnect the fuel supply line at the quick-connect fitting near the cowl.
132. Install the appropriate Fuel Line Adapters / Fitting from the Decay Tool, Fuel 8978A. Route the opposite
end of this hose to a diesel fuel draining station.
NOTE: Activation of the fuel pump module may time out and need to be restarted several times to
completely drain the fuel tank.
133. Using a diagnostic scan tool, activate the fuel pump module until the fuel tank has been evacuated.
Alternative Procedure
NOTE: If the electric fuel pump is not operating, the fuel tank must be removed and drained through
the fuel pump module opening of the fuel tank.
134. Raise and support the vehicle.
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.
Figure 76 – CCV Harness Retainer and
Connector
SAFETY RECALL – NORTH AMERICA
High Pressure Fuel Pump
Reference: 01A / NHTSA 23V-263
FCA US LLC
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135. Using a suitable hydraulic jack with a fuel tank adapter, support the fuel tank.
136. Remove the nuts (1) from the tank straps (Figure 77).
137. Remove both fuel tank straps (2) (Figure 77).
138. Disconnect the return fuel line quick-connect
fitting (1) at the front of fuel tank (Figure 78).
139. Disconnect the two fuel vent line quick-connect
fittings (2) (Figure 78).
140. Disconnect the fuel supply line quick-connect
fitting (4) (Figure 78).
141. Disconnect the fuel filler vent line quick-connect
fitting (3) at the fuel pump module (Figure 78).
Figure 77 – Tank Straps
Figure 78 – Top View of Tank
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142. Disconnect the fuel pump module wire harness
connector (1) (Figure 79).
143. Loosen the clamp (2) and disconnect fill hose
from fuel tank (Figure 80).
144. Remove the fuel vent lines from the retaining
clips (1) (Figure 80).
145. Lower the fuel tank and remove from hydraulic
jack.
CAUTION: An indexing arrow is located on top
of the main fuel pump module to clock its
position into the fuel tank, note its location for
reassembly.
CAUTION: When positioning the Fuel Pump
Lock Ring Wrench, do so that the tool will not
contact the fuel return fitting. Failure to do so
may result in breaking the fitting.
NOTE: Prior to removing the fuel pump
module, use compressed air to remove any accumulated dirt and debris from around fuel tank
opening.
Figure 79 – Pump Module Connector
Figure 80 – Tank Connections
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146. Position the 9340 SAE Fuel Pump Lock Ring
Wrench in the notches on the outside edge of
the lock ring (1) (Figure 81).
147. Install a 1/2-inch drive breaker bar into the top of
the lock ring remover/installer.
148. Rotate the breaker bar counterclockwise and
remove the lock ring (1) (Figure 81).
CAUTION: Whenever the fuel pump module is
serviced, the rubber O-ring seal must be
replaced.
149. Remove the fuel pump module (2) from the fuel
tank and discard (Figure 81).
150. Ensure the swirl pot indentation below the intank
electric fuel pump inlet is completely
drained of any contaminated fuel and thoroughly
clean the fuel tank.
151. Completely drain the low-pressure fuel lines and flush with clean diesel fuel, then install a NEW fuel filter.
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.
152. Make sure the fuel return tube (1) is inside the
cup (Figure 82).
153. Using a NEW rubber O-ring seal, position the
NEW fuel pump module into the fuel tank
opening.
Figure 81 – Tank Connections
Figure 82 – Fuel Return Tube
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154. Position the lock ring (1) over top of the fuel
pump module (2) (Figure 83).
155. Rotate the fuel pump module (2) 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 (Figure 83).
CAUTION: When positioning the Fuel Pump
Lock Ring Wrench, do so that the tool will not
contact the fuel return fitting. Failure to do so
may result in breaking the fitting.
156. Install the 9340 SAE Fuel Pump Lock Ring
Wrench in the notches on the outside edge of
the lock ring (1) (Figure 83).
157. Install a 1/2 inch drive breaker bar into the SAE
Fuel Pump Lock Ring Wrench.
158. Rotate the breaker bar clockwise until all seven notches of the lock ring (1) have engaged (Figure 83).
159. Secure the fuel tank onto a suitable hydraulic jack with a fuel tank adapter.
160. Raise and position the fuel tank leaving room to make the connections at the top of the fuel tank.
161. Install the fuel vent lines into the retaining clips
(1) (Figure 84).
162. Install the fuel fill hose and securely tighten the
clamp (2) (Figure 84).
Figure 83 – Tank Connections
Figure 84 – Tank Connections
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163. Connect the fuel pump module wire harness
connector (1) (Figure 85).
164. Connect the fuel filler vent line quick-connect
fitting (3) to the fuel pump module (Figure 86).
165. Connect the fuel supply line quick-connect fitting
(4) (Figure 86).
166. Connect the fuel vent line quick-connect fittings
(2) (Figure 86).
167. Connect the return fuel line quick-connect fitting
(1) at the front of fuel tank (Figure 86).
168. Raise the fuel tank until snug to the body.
Figure 85 – Tank Module Connections
Figure 86 – Tank Connections
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169. Install the fuel tank straps (2) and tighten the
nuts (1) to 54 N·m (40 ft. lbs.) (Figure 87).
170. Remove the hydraulic jack.
171. Lower the vehicle and add 5 gallons of clean
diesel fuel to the tank.
172. Connect a clean hose to the low-pressure fuel
line at the high pressure fuel pump fitting and
place the other end in a suitable clean
container.
173. Install the negative battery cable eyelet to the
IBS stud and secure using the nut. Tighten the
nut to 5 N·m (44 in. lbs.).
NOTE: Overtightening of the nut connecting
the negative cable to the IBS will cause
damage to the IBS or break the stud for the
nut.
174. Connect the IBS wire harness connector if the negative battery cable clamp was removed.
175. Turn the ignition ON, and collect the fuel escaping from the low pressure feed into a clean container.
176. Connect the lower pressure supply line (2) to the high pressure pump (Figure 74).
177. Install the fuel injection pump silencer (1)
(Figure 88).
Figure 87 – Fuel Tank Straps
Figure 88 – Pump Silencer
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178. Install the fuel injection pump blocker shield (2)
and tighten the bolts (1) to 25 N·m (18 ft. lbs.)
(Figure 89).
179. Install the fuel injection pump silencer (1) and
the fasteners (2) (Figure 90).
Figure 89 – Pump Blocker Shield
Figure 90 – Pump Silencer
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180. Start the engine and check for leaks at all fuel
connections.
181. Install the engine cover (2) and securely tighten
the bolts (1) (Figure 91).
Figure 91 – Engine Cover
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B. JL Vehicles
For vehicles with a contaminated fuel system, use the procedure below.
Remove
WARNING: High-pressure lines deliver diesel fuel under extreme pressure from the injection pump to
the fuel injectors. This may be as high as 2000 bar (29,008 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.
WARNING: Observe the following precautions when working on fuel systems: No sparks, open flames
or smoking. Avoid inhaling and swallowing fuel. Avoid eye and skin contact with fuel. Pour fuels only
into suitable and appropriately marked containers. Wear protective clothing. Failure to observe these
precautions may result in fire, explosion, property damage, and serious or fatal injury.
WARNING: High-pressure lines deliver diesel fuel under extreme pressure from the injection pump to
the fuel injectors. This may be as high as 2000 bar (29,008 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.
WARNING: Observe the following precautions when working on fuel systems: 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: When key is cycled to the off position, fuel system pressure automatically bleeds down.
NOTE: The fuel injection pump can be replaced without having to perform the entire base engine valve
timing procedure. This procedure gives instruction on how to remove and install the new fuel injection
pump without performing the base engine timing. Do not rotate the pump shaft after removing from the
vehicle. The alignment of the pump shaft must be measured and recorded using a commercially
available degree wheel after the pump is removed and before transferring the pump gear over to the
new pump. This is done to align the pump to the same position during installation. If the base engine
valve timing must be performed as part of the repair, refer to Service Library 09 – Engine/Valve
Timing/Standard Procedure.
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Battery Disconnect
1. On this dual battery system the auxiliary battery ground cable connects to the main battery cable end
(shown in generic graphic) and grounds through the main battery ground cable connection to the body,
chassis or engine (depending on vehicle). Therefore, simply disconnecting and isolating the main battery
negative cable clamp from the main battery post will not isolate the auxiliary from the vehicle’s electrical
system. The auxiliary battery will still be grounded through it’s connection to the main battery negative
cable end. If both battery negative cables are not isolated it will result in the vehicle electrical system and
Power Distribution Center (PDC) still having battery connection which can cause vehicle wiring damage or
deployment of air bags on re-connection (Figure 92). In Service Library, see 08 – Electrical / 8F – Engine
Systems / Battery System / Standard Procedure / Battery Disconnect – Dual 12 Volt Battery System.
2. Turn the ignition off. Wait five minutes to allow the main modules to go to sleep.
3. Disconnect and isolate the supplemental (auxiliary) battery negative cable from the main battery negative
cable end. This will disconnect and isolate the auxiliary battery ground.
4. The main battery ground can be disconnected by removing the main battery negative cable from the
negative battery cable end, or by disconnecting the IBS connector, loosening the negative battery clamp
nut and removing the negative battery cable end from the battery post. Either method will disconnect the
main battery. Both batteries should be disconnected from the vehicle electrical system.
5. Measure the voltage at the PDC positive battery cable connection to verify the vehicle electrical system is
powered down.
Figure 92 – Dual Battery System
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NOTE: On some vehicles a small amount of voltage may be present (typically less than
approximately 0.5 volts) due to capacitors is some modules still having voltage stored. Anything
less than 1.0 volts should be safe.
6. Remove the engine cover (Figure 93).
PUMP COVER – Remove
7. Remove the clamp at the turbocharger air inlet
elbow (1). Slide the CCV hose (2) off at the head.
Disconnect the Mass Air Flow connector (3)
(Figure 94).
8. Remove the air cleaner body bolt then lift up and
the air cleaner body and remove it and the clean
air hose as an assembly.
Figure 94 – Inlet Air Tube
1
2
3
Figure 93 – Engine Cover
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9. Release the retaining lock (1) and disconnect the
Charge Air Cooler (CAC) hose from the EGR air
flow control valve (Figure 95).
10. Loosen the left CAC hose clamp and disconnect
the left CAC hose from the CAC and remove it
(Figure 96).
Figure 95 – CAC Hose from EGR Air
Flow Control Valve
Figure 96 – CAC Hose from Intercooler
CAC HOSE
INTERCOOLER CLAMP
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11. Remove the fuel injection pump blocker plate bolts
(2) and the fuel injection pump blocker plate (1)
from the fuel injection pump (Figure 97).
12. Disconnect the low-pressure fuel supply/return
lines (4) (Figure 98).
13. Disconnect the fuel quantity solenoid wire harness
connector (2) (Figure 98).
14. Remove the fuel rail supply tubes (1 and 3) from
the HPFP (Figure 98).
Figure 98 – Fuel Rail Supply Tubes
Figure 97 – Blocker Plate
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RIGHT SIDE – Remove
15. Remove the Charge Air Cooler (CAC) hose bolt
(2) (Figure 99).
16. Release the retaining clip (1) and disconnect the
CAC hose from the turbocharger elbow and
position aside.
17. Loosen the fuel rail cover nut (3), detach the wire
harness retainer (1) and remove the fuel rail cover
(2) (Figure 100).
Figure 99 – CAC Hose
Figure 100 – Fuel Rail Cover
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18. Remove fasteners from coolant hose support
brackets at the front and rear of the engine
(Figure 101 and 102).
Figure 101 – Front Coolant Hose
Bracket
Figure 102 – Rear Coolant Hose
Bracket
BRACKET
BRACKET
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19. Remove the upper Exhaust Gas Recirculation
(EGR) tube bolts (1) (Figure 103).
20. Remove the lower EGR tube bolts (2) and the
EGR tube (1) (Figure 104).
21. Remove and discard both gaskets.
Figure 103 – Upper EGR Tube
Figure 104 – Lower EGR Tube
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22. Lift up on locking tabs (1) to unlock the locks (2)
on the right bank fuel return hoses on the tops of
the injectors (Figure 105).
23. Remove the fuel return hoses (2) by wiggling
hoses free from the fuel injector (Figure 105).
NOTE: Use a backing wrench on the fuel
injector when unscrewing the union nut.
24. Unscrew the union nuts (7 and 9) and remove
cylinder No. 1 fuel tube (8) and the discard fuel
tube (Figure 106).
25. Unscrew the union nuts (4 and 6) and remove
cylinder No. 2 fuel tube (5) and discard the fuel
tube (Figure 106).
26. Unscrew the union nuts (1 and 3) and remove
cylinder No. 3 fuel tube (2) and discard the fuel
tube (Figure 106).
Figure 105 – Fuel Return Hoses
Figure 106 – Right Fuel Injector Tubes
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LEFT SIDE – Remove
27. Remove the vent hose (1) from the left fuel rail
cover (Figure 107).
28. Remove the left fuel rail cover bolts (1) and the left
fuel rail cover (2) (Figure 108).
Figure 107 – Vent Hose
Figure 108– Fuel Rail Cover
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29. Lift up on locking tabs (1) to unlock the locks on
the fuel return hoses on the tops of the injectors
(Figure 109).
30. Disconnect the fuel return lines by wiggling the
hoses free from the fuel injectors (Figure 109).
NOTE: Use a backing wrench on the fuel
injector when unscrewing the union nut.
31. Unscrew the union nuts (1 and 3) and remove
cylinder No. 4 fuel tube (2) and discard the fuel
tube (Figure 110).
32. Unscrew the union nuts (4 and 6) and remove
cylinder No. 5 fuel tube (5) and discard the fuel
tube (Figure 110).
33. Unscrew the union nuts (7 and 9) and remove
cylinder No. 6 tube (8) and discard the fuel tube
(Figure 110).
Crossover Tube – Remove
34. Detach the vacuum line from the coolant bottle
bracket.
35. Remove the coolant bottle bolts and position aside
the coolant bottle.
36. Detach the brake booster vacuum hose from the bracket.
Figure 110 – Fuel Injector Tubes
Figure 109 – Fuel Return Hoses
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37. Disconnect the differential pressure sensor wire
harness connector (1) (Figure 111).
38. Disconnect the differential pressure sensor hoses
(1) (Figure 112).
39. Remove the differential pressure sensor nut (3)
and the differential pressure sensor (2)
(Figure 112).
Figure 111 – Pressure Sensor
Connector
Figure 112 – Differential Pressure
Sensor
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40. Remove the low pressure EGR valve to the upper
turbocharger inlet elbow bolts and remove the
upper turbocharger inlet elbow (Figure 113).
41. Remove and DISCARD the low pressure EGR
valve gasket (1) (Figure 113).
42. Remove and DISCARD the lower turbocharger
inlet elbow gasket (1) (Figure 114).
43. Disconnect the boost pressure sensor wire
harness connector.
44. Disconnect the swirl valve wire harness
connector.
45. Disconnect the fuel pressure sensor wire harness
connector.
Figure 113 – Upper Turbo Inlet Elbow
Gasket
Figure 114 – Lower Turbo Inlet Elbow
Gasket
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46. Remove the fuel crossover tube bolt (1)
(Figure 115).
47. Unscrew the union nuts (1 and 3) and remove the
fuel crossover tube (2) and discard (Figure 116).
Figure 115 – Crossover Tube Bolt
Figure 116 – Crossover Tube Bolt
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Left Fuel Rail Supply Tube – Remove
48. Remove the left fuel tube bracket nut (1) securing
the fuel tube (Figure 117).
49. Unscrew the union nut (2) from the fuel rail and
remove and discard the fuel tube (Figure 117).
Right Fuel Rail Supply Tube – Remove
50. Release the retaining clip (1) and disconnect the
CAC hose from the EGR air flow control valve
(Figure 118).
Figure 117 – Left High Pressure Fuel
Tube Nut
Figure 118 – CAC Hose Clip
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51. Remove the fuel tube bolt (2) securing the fuel
tube (Figure 119).
52. Unscrew the union nut (1) and remove and
discard the fuel tube (3) (Figure 119).
53. Install protective caps over the openings.
Fuel Injector Return Lines – Remove
54. Lift up on locking tabs (1 and 3) at each injector to
unlock the locks (Figure 120).
55. Remove the fuel return lines by wiggling hose free
from the fuel injectors (Figure 120).
56. Remove the fuel line retainers (2) and detach the
fuel injector return line from the main fuel return
line (4) (Figure 120).
Figure 119 – Right High-Pressure Fuel
Tube Bolt
Figure 120 – Injector Return Lines
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57. Detach the fuel return line retainers (1 and 2)
(Figure 121).
58. Remove the fuel injector return line assembly (3)
(Figure 121).
Fuel Injector Rails – Remove
59. Disconnect the fuel pressure regulator wire
harness connector (1) on the LEFT rail
(Figure 122).
Figure 121 – Injector Return Line
Retainers
Figure 122 – Fuel Pressure Regulator
Connector (Left Rail)
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60. Using the Remover-Installer, Fuel Rail Bolt
2025400090, remove the left fuel rail bolts (2) and
the left fuel rail (1) (Figure 123).
61. Disconnect the fuel pressure sensor harness
connector (1) on the RIGHT rail (Figure 124).
Figure 123 – Left Fuel Rail
Figure 124 – Fuel Pressure Sensor
Right Fuel Rail
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62. Using the Remover-Installer, Fuel Rail Bolt
2025400090, remove the right fuel rail bolts (2)
and the right fuel rail (1) (Figure 125).
Fuel Injectors – Remove
63. Disconnect the fuel injector wire harness
connectors (1) (Figure 126).
64. Clean the area around the fuel injectors so that no
debris falls into the injector bores.
Figure 125 – Right Fuel Rail
Figure 126 – Fuel Injector Wire Harness
Connectors
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65. Remove the fuel injector clamp bolts (1) and the
fuel injector clamps (2) (Figure 127).
66. Using your hand, pull the fuel injectors (1) straight
up from the cylinder head for removal. Discard the
lower sealing washer and place a protective cap
over the injector bore (Figure 128).
Figure 127 – Fuel Injector Clamps
Figure 128 – Fuel Injectors
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67. If an injector can’t be removed by hand, install the
Remover, Fuel Injector VM.10358A (1) to remove
the fuel injector. Discard lower sealing washer and
place a protective cap over the injector bore
(Figure 129).
NOTE: Check and MAKE SURE that the copper
sealing washer did not remain in the cylinder
head.
NOTE: Steps 68 – 69 necessary for fuel injector
No. 3.
68. Disconnect the EGR cooler vacuum bypass hose
(1) (Figure 130).
Figure 129 – Remover, Fuel Injector
VM.10358A
Figure 130 – EGR Cooler Vacuum
Bypass Hose
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69. Remove the vacuum actuator with heat shield
screws (1) and position aside the vacuum actuator
(Figure 131).
NOTE: When a NEW fuel injector is being
installed, or if an existing injector is installed
in any location other than its original location,
the injector quantity adjustment procedure
must be performed (Refer to 14 – Fuel
System/Fuel Injection – Standard Procedure).
HIGH PRESSURE FUEL PUMP – Remove and Replace
NOTE: The fuel injection pump can be replaced without having to perform the entire base engine
valve timing procedure. Do not rotate the pump shaft after removing from the vehicle. The
alignment of the pump shaft must be measured and recorded using a commercially available
degree wheel after the pump is removed and before transferring the pump gear over to the new
pump. This is done to align the pump to the same position during installation. If the base engine
valve timing must be performed as part of the repair (Refer to 09 – Engine/Valve Timing/Standard
Procedure).
Figure 131 – Vacuum Actuator Screws
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70. Remove the upper bolts (1) from the highpressure
pump (Figure 132). Using Tool, High
Pressure Pump Installation VM.10345 Install the
studs in the upper locations.
71. Remove the lower bolt (1) from the HPFP (2) and
slide the pump away from the engine as far as
possible (Figure 133).
72. While holding the pump in place, remove the VM.
10345 pins, then remove the pump from the
vehicle.
NOTE: The fuel injection pump needs to be
timed using a commercially available degree
wheel.
Figure 132 – Fuel Quantity Solenoid
Connector and HPFP Upper Bolts
Figure 133 – HPFP Lower Bolt
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73. Install the degree wheel onto the pump and record
the position of the hole in the gear on the degree
wheel (Figure 134).
74. The use of Puller 1023 or a commercially
available gear puller is required to remove the fuel
injection pump gear (Figure 134).
NOTE: The use of Puller 1023 or a
commercially available gear puller is required
to remove the fuel injection pump gear (2)
(Figure 135).
CAUTION: Do Not Force the high-pressure
pump into the right timing cover or attempt to
seat it by drawing it in with the bolts. The
pump gear must be properly aligned with the
drive gear on the camshaft before the highpressure
pump will seat on the cylinder head
mounting surface. Failure to properly align
drive gears will damage the high-pressure
pump or camshaft drive gear.
Figure 134 – Degree Wheel
Figure135 – Gear Removal
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75. Install a NEW O-ring seal (1) to the fuel injection
pump (Figure 136).
76. Install the gear (2) and nut (1) onto the fuel
injection pump (3) and tighten the nut (1) finger
tight (Figure 137).
Note: NEVER use an impact to tighten the gear
nut.
Figure 136 – O-ring Seal
Figure 137 – O-ring Seal
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77. Using a commercially available spanner wrench
(2) such as Blue Point APS35IB or equivalent,
tighten the nut (1) to 50 N·m (37 ft. lbs.)
(Figure 138).
78. Install the degree wheel and rotate the pump shaft
so that the hole aligns with the reference mark on
the degree wheel referenced during the removal
(Figure 139).
79. While holding the pump in place, install the VM.
10345 pins in the upper timing cover.
80. Install the pump to the engine using the pins as a
guide. Install the lower fuel injection pump bolt (1)
and hand tighten the bolt (Figure 133).
81. Remove the Tool, High Pressure Pump
Installation VM.10345 from the upper bolts
location and install the bolts.
82. Tighten the bolts (1) that secure the fuel injection
pump to 25 N·m (18 ft. lbs.) (Figures 133 and
132).
Figure 138 – Nut with Spanner Wrench
Figure 139 – Degree Wheel
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83. Remove the protective cap from the appropriate injector bore.
NOTE: Make sure the old copper sealing washer is not stuck in bore.
84. Clean the fuel injector bore (Refer to 09 –
Engine/Fuel Injection/INJECTORS,
Fuel/Cleaning).
85. Install a NEW fuel injector seal (1) in the cylinder
head cover (Figure 140).
Figure 140 – Upper Sealing Washer
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86. Install a NEW sealing washer (2) onto the fuel
injector (1) (Figure 141).
NOTE: Do Not apply any lubricant to the fuel
injector nozzle. Care must be taken not to
restrict the discharge orifices in the nozzle.
87. Lubricate the NEW injector body with Nickel Anti-
Seize Lubricant (Figure 142).
Figure 141 – Lower Sealing Washer
Figure 142 – Lubricate the Fuel Injector
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88. Install the fuel injector (1) in the cylinder head
(Figure 143).
89. Install the fuel injector clamp (2) and tighten the
bolt (1) to 33 N·m (24 ft. lbs.) (Figure 144).
Figure 143 – Fuel Injector Bolt
Figure 144– Fuel Injector Bolt and
Clamp
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90. Install the NEW fuel rails. Using the Remover-Installer, Fuel Rail Bolt 2025400090 tighten the bolts to 25
N·m (18 ft. lbs.).
91. Connect the fuel pressure sensor harness connector on the RIGHT rail (Figure 124).
92. Install the vacuum actuator with heat shield screws (1) (Figure 131).
93. Install the EGR cooler vacuum bypass hose (1). Be sure this hose is fully seated (Figure 130).
94. Install the fuel injector wire harness connectors (1) (Figure 126).
95. Install the fuel pressure regulator wire harness connector on the LEFT rail (Figure 122).
96. Install low-pressure fuel return line to the hard lines and to the return side of the pump. Leave the fuel
supply side disconnected from the pump at this time.
97. Connect the fuel quantity solenoid wire harness connector (2) (Figure 98).
98. Install a NEW fuel crossover tube (2) and tighten the union nuts (1, 3) to 11 N·m + 75° (8 ft. lbs. + 75°)
(Figure 116).
99. Install the fuel crossover tube bolt (1) and tighten securely (Figure 115).
100. Connect the fuel pressure sensor wire harness connector.
101. Connect the swirl valve wire harness connector.
102. Connect the boost pressure sensor wire harness connector.
103. Install a NEW lower turbocharger inlet elbow gasket (Figure 114).
104. Install a NEW low pressure EGR valve gasket (Figure 113).
105. Install the upper turbocharger inlet elbow and the low pressure EGR valve to the upper turbocharger inlet
elbow bolts and tighten to 11 N·m (8 ft. lbs.) (Figure 113).
106. Install the differential pressure sensor and securely tighten the differential pressure sensor nut
(Figure 112).
107. Connect the differential pressure sensor hoses (1) (Figure 112).
108. Connect the differential pressure sensor wire harness connector (1) (Figure 111).
109. Attach the brake booster vacuum hose from the bracket.
110. Install the coolant bottle, bracket, and nuts, and tighten the nuts to 10 N·m (89 In. Lbs.).
111. Attach the vacuum line to the coolant bottle bracket.
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NOTE: The fuel tubes are a one-time only use and must be replaced anytime they have been
removed.
NOTE: Use a backing wrench on the fuel injector when tightening the union
nut.
112. Install the NEW fuel rail supply tubes (1 and 3) at the HPFP and rails. Tighten both ends to 11 N·m + 75°
(8 ft. lbs. + 75°) (Figures 98, 117 and 119).
113. Connect the CAC hose from the EGR air flow control valve and secure the retaining clip (1) (Figure 118).
114. Install the fuel tube bracket bolts and securely tighten.
115. Install the NEW right side fuel tubes (Figure 106):
• Remove the protective caps from cylinder No. 3 fuel injector and fuel rail.
• Install the NEW fuel tube to cylinder No. 3 and tighten the union nuts finger tight.
• Remove the protective caps from cylinder No. 2 fuel injector and fuel rail.
• Install the NEW fuel tube to cylinder No. 2 and tighten the union nuts finger tight.
• Remove the protective caps from cylinder No. 1 fuel injector and fuel rail.
• Install the NEW fuel tube to cylinder No. 1 and tighten the union nuts finger tight.
• Tighten the fuel rail union nuts to 11 N·m + 75° (8 ft. lbs. + 75°).
• Tighten the fuel injector union nuts to 11 N·m + 75° (8 ft. lbs. + 75°).
116. Install the NEW left side fuel tubes (Figure 110):
• Remove the protective caps from cylinder No. 6 fuel injector and fuel rail.
• Install the NEW fuel tube to cylinder No. 6 and tighten the union nuts finger tight.
• Remove the protective caps from cylinder No. 5 fuel injector and fuel rail.
• Install the NEW fuel tube to cylinder No. 5 and tighten the union nuts finger tight.
• Remove the protective caps from cylinder No. 4 fuel injector and fuel rail.
• Install the NEW fuel tube to cylinder No. 4 and tighten the union nuts finger tight.
• Tighten the fuel rail union nuts to 11 N·m + 75° (8 ft. lbs. + 75°).
• Tighten the fuel injector union nuts to 11 N·m + 75° (8 ft. lbs. + 75°).
NOTE: Do not use any type of lubrication when installing the fuel injector return hose.
117. Install the fuel injector return hose assembly. Install the fuel injector return hose and be sure it is fully
seated. Push down on the lock tab to lock in place (Figures 120 and 121).
118. Install the left fuel rail cover (2) and the left fuel rail cover bolt (1) and tighten securely (Figure 108).
119. Install the vent hose (1) to the left fuel rail cover (Figure 107).
120. Install the lower EGR tube (1) and the EGR tube bolts (2) and tighten to 25 N·m (18 Ft. Lbs.) (Figure 104).
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121. Install the upper Exhaust Gas Recirculation (EGR) tube bolts (1) and tighten to 11 N·m (8 Ft. Lbs.)
(Figure 103).
122. Install fasteners to coolant hose support brackets at the front and rear of the engine and tighten securely
(Figure 101 and 102).
123. Install the fuel rail cover (2), attach the wire harness retainer (1), and securely tighten the right fuel rail
cover nut (3) (Figure 100).
124. Connect the CAC hose to the turbocharger elbow and fasten the retaining clip (Figure 99).
125. Install the Charge Air Cooler (CAC) hose bolt (2) and tighten to 11 N·m (8 Ft. Lbs.) (Figure 99).
126. Remove all fuel from the fuel tank. (Refer to 09 – Engine/Fuel System/Standard Procedure) Use an
appropriate fuel container. Dispose of the contaminated fuel using the proper procedures.
CAUTION: Dispose of petroleum-based products in a manner consistent with all applicable Local,
State, Federal, and Provincial regulations.
127. Remove the fuel tank (Refer to 09 – Engine/Fuel System/TANK, Fuel/Removal and Installation).
128. Ensure the swirl pot indentation below the in-tank electric fuel pump inlet is completely drained of any
contaminated fuel and thoroughly clean the fuel tank.
129. Completely drain the low-pressure fuel lines and flush with clean diesel fuel, then install a NEW fuel filter.
130. Install the fuel tank and fill with clean diesel fuel.
131. Install the appropriate Fuel Line Adapters / Fitting from the Decay Tool, Fuel 8978A to the low-pressure
feed pipe at the HPFP. Route the opposite end of this hose into a suitable container.
132. Using a diagnostic scan tool, activate the fuel pump to fully purge the low-pressure feed line from the tank
to the HPFP.
133. Connect the low-pressure feed line to the HPFP.
134. Connect a clean hose to the low pressure return line fitting at the tank and place the other end in a suitable
clean container.
135. Using a diagnostic scan tool, activate the fuel pump to fully purge the low-pressure fuel return from the
HPFP to the tank.
136. Connect the low pressure return line at the tank.
137. Install the fuel tank (Refer to 09 – Engine/Fuel System/TANK, Fuel/Removal and Installation).
138. Connect the negative battery cable(s). In Service Library, see 08 – Electrical / 8F – Engine Systems /
Battery System / Standard Procedure / Battery Disconnect – Dual 12 Volt Battery System.
139. Start the engine and check for leaks.
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140. Install the fuel injection pump blocker plate and the fuel injection pump blocker plate bolts to the fuel
injection pump and tighten to 25 N·m (18 Ft. Lbs.) (Figure 97).
141. Connect the left CAC hose to the CAC and tighten the left CAC hose clamp (Figure 96).
142. Connect the Charge Air Cooler (CAC) hose to the EGR air flow control valve and secure the retaining lock
(1) (Figure 95).
143. Set the air cleaner body (2) and the clean air hose (1) as an assembly into place and press down to seat it
on its retainer. Install the air cleaner body bolt (3) and tighten to 5 N·m (44 In. Lbs.) (Figure 94).
144. Install the clamp at the turbocharger air inlet elbow (1). Slide the PCV hose (2) on at the head. Connect the
Mass Air Flow electrical connector (3) (Figure 94).
145. Install the engine cover and engine cover bolts and tighten to 4 N·m (35 In. Lbs.) (Figure 93).
146. Close the hood and return the vehicle to the customer.
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For vehicles with a non-contaminated fuel system, use the procedure below.
C. DT Vehicles
Replace HPFP – Non-Contaminated System
WARNING: High-pressure lines deliver diesel fuel under extreme pressure from the injection pump to
the fuel injectors. This may be as high as 2000 bar (29,008 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.
WARNING: Observe the following precautions when working on fuel systems: No sparks, open flames
or smoking. Avoid inhaling and swallowing fuel. Avoid eye and skin contact with fuel. Pour fuels only
into suitable and appropriately marked containers. Wear protective clothing. Failure to observe these
precautions may result in fire, explosion, property damage, and serious or fatal injury.
WARNING: High-pressure lines deliver diesel fuel under extreme pressure from the injection pump to
the fuel injectors. This may be as high as 2000 bar (29,008 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.
WARNING: Observe the following precautions when working on fuel systems: 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: When key is cycled to the off position, fuel system pressure automatically bleeds down.
NOTE: The fuel injection pump can be replaced without having to perform the entire base engine valve
timing procedure. This procedure gives instruction on how to remove and install the new fuel injection
pump without performing the base engine timing. Do not rotate the pump shaft after removing from the
vehicle. The alignment of the pump shaft must be measured and recorded using a commercially
available degree wheel after the pump is removed and before transferring the pump gear over to the
new pump. This is done to align the pump to the same position during installation. If the base engine
valve timing must be performed as part of the repair, refer to Service Library 09 – Engine/Valve
Timing/Standard Procedure.
This procedure is for the removal and installation of the fuel injection pump only. The fuel injection pump
can be replaced without needing to perform the entire base engine valve timing procedure. This procedure
gives instruction on how to properly align the new fuel injection pump. If the base engine valve timing
must be performed, (Refer to 09 – Engine/Valve Timing/Standard Procedure). The timing of the pump is
crucial and the gear must not be moved once the pump is removed from the timing cover.
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1. Remove and isolate the negative battery cable
eyelet from the IBS. This will isolate the 12 volt
from the vehicle electrical system (Figure 144).
NOTE: If removing the negative battery cable
clamp from the battery post instead of
removing the negative battery cable eyelet, the
Intelligent Battery Sensor (IBS) wire harness
connector must be disconnecting prior to
removing the cable end. Failure to disconnect
the IBS wire harness connector can lead to
damage of the IBS wire harness connector.
2. Disconnect the negative battery cable by
removing the ground terminal nut (1) (Figure 144).
3. Remove the two bolts (1) securing the engine
cover (2) (Figure 145).
4. Lift up and pull forward and remove the engine
cover (2) (Figure 145).
Figure 144 – Battery Disconnect
Figure 145 – Engine Cover
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5. Loosen the clamp (1) and disconnect the clean air
hose (Figure 146).
6. Detach the coolant hose retainer (2) from the
clean air hose (Figure 146).
7. Remove the bolt (3) securing the clean air hose
(Figure 146).
8. Disconnect the Closed Crankcase Heater
Ventilation (CCV) heater wire harness connector
(1) (Figure 147).
9. Detach the CCV heater wire harness retainer (2)
(Figure 147).
10. Disconnect the crankcase breather hose.
Figure 146 – Clean Air Hose
Figure 147 – Closed Crankcase
Ventilation Connector
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11. Loosen clamp (1) and remove the clean air hose
(2) (Figure 148).
12. Remove the fastener (1) securing the right Charge
Air Cooler (CAC) hose (Figure 149).
13. Release the retaining lock (2) and disconnect the
right CAC hose from the turbocharger
(Figure 149).
Figure 148 – Clean Air Hose
Figure 149 – CAC Hose
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14. Remove the retainers (1) that secure the cover (2)
for the high-pressure fuel pump (Figure 150).
15. Remove the bolts (1) securing the sound proofing
(2) to the fuel injection pump (Figure 151).
Figure 150 – Pump Cover
Figure 151 – Pump Sound Proofing
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16. Disconnect the fuel injection pump electrical
connector (2) (Figure 152).
17. Remove the vent hose (1) from the left fuel rail
cover (Figure 153).
Figure 152 – Pump Connections
Figure 153 – Left Bank Fuel Rail Cover
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18. Remove the bolts (2) and the left fuel rail cover (1)
(Figure 154).
19. Disconnect the low-pressure supply (2) and return
(1) lines from the fuel injection pump (Figure 155).
Figure 154 – Left Bank Fuel Rail Cover
Bolts
Figure 155 – Low Pressure Supply and
Return Connections
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20. Remove the fuel line supply safety clip (1)
(Figure 156).
21. Disconnect the fuel supply (2) and return (1) lines
(Figure 157).
Figure 156 – Safety Clip
Figure 157 – Fuel Supply and Return
Lines
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22. Disconnect the fuel return lines (1, 2) (Figure 158).
23. Remove the fuel supply line bolt (3) and return line
bolt (4) and both lines (Figure 158).
24. Detach the retainers (1) securing the fuel return
hose to the fuel line support bracket (Figure 159).
Figure 158 – Return Lines (1,2) and
Bolts (3,4)
Figure 159 – Return Hose Retainers
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25. Detach the wire harness retainer (3) (Figure 160).
26. Remove the bolts (1) fuel line support bracket (2)
(Figure 160).
27. Unscrew the union nut (1) from the fuel injection
pump (Figure 161).
Figure 160 – Return Hose Retainers
Figure 161 – Union Nut
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28. Remove the bolt (1) securing the fuel tube
(Figure 162).
29. Unscrew the union nut (2) and remove the fuel
tube (1) and then discard the fuel tube
(Figure 163).
Figure 162 – Pipe Bolt
Figure 163 – Tube Union Nut
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30. Remove and discard the right-side fuel tubes (5,
2) from fuel injectors No. 1 and 2 (Figure 164).
31. Remove the nut (1) securing the fuel tube
(Figure 165).
Figure 164 – Fuel Tubes
Figure 165 – Pipe Nut
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32. Unscrew the union nuts (1, 3) and remove and
discard the fuel tube (2) (Figure 166).
33. Remove the upper bolts (1) from the highpressure
pump (2) (Figure 167).
Figure 166 – Union Nuts
Figure 167 – Upper Bolts
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34. Using the Tool, High Pressure Pump Installation VM.10345 install the studs in the upper locations.
NOTE: The timing of the pump is crucial, and the gear must not be moved once the pump is
removed from the timing cover.
35. Remove the lower bolt (1) from the HPFP (2) and
remove it from the vehicle (Figure 168).
NOTE: The fuel injection pump needs to be
timed using a commercially available degree
wheel.
36. Install the degree wheel onto the pump with the
zero at the fuel quantity solenoid then mark the
location of the hole in the gear on the degree
wheel (Figure 169).
Figure 168 – Lower Bolt
Figure 169 – Installing a Printed Paper
Degree Wheel from the Internet
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37. Using a commercially available spanner wrench
such as Blue Point APS35IB, Snap-on APS351C
or equivalent to hold fuel injection pump gear.
Remove the fuel injection pump gear nut
(Figure 170).
38. The use of Puller 1023 or a commercially
available gear puller is required to remove the fuel
injection pump gear (2) (Figure 171).
WARNING: High-pressure lines deliver diesel
fuel under extreme pressure from the injection
pump to the fuel injectors. This may be as high
as 2000 bar (29,008 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.
CAUTION: Do Not Force the high-pressure
pump into the right timing cover or attempt to
seat it by drawing it in with the bolts. The
pump gear must be properly aligned with the
drive gear on the camshaft before the highpressure
pump will seat on the cylinder head mounting surface. Failure to properly align drive
gears will damage the high-pressure pump or camshaft drive gear.
NOTE: The high-pressure pump needs to be timed before it can be installed. Use a commercially
available degree wheel to time the high-pressure pump.
Figure 171 – Swapping the Drive Gear
on the HPFP
Figure 170 – Installing the Drive Gear
on the HPFP
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39. If removed, install the gear (2) and nut (1) onto the high-pressure pump (3) and tighten the nut (1) finger
tight (Figure 171).
40. Using a commercially available spanner wrench (2) such as Blue Point APS35IB or equivalent and tighten
the nut (1) to 50 N·m (37 Ft. Lbs.) (Figure 170).
41. Install the degree wheel with the zero in line with
the fuel quantity solenoid and rotate the pump
shaft so that the hole aligns with the reference
mark on the degree wheel referenced during the
removal (Figure 172).
42. Install a NEW O-ring seal (1) to the high-pressure
fuel injection pump (Figure 173).
Figure 172 – Installing a Printed Paper
Degree Wheel from the Internet
Figure 173 – HPFP O-ring
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43. Install the HPFP onto the Tool, High Pressure
Pump Installation VM.10345 installed in the upper
timing cover.
44. Install the HPFP (2) and hand tighten the bolt (1)
(Figure 174).
45. Remove the Tool, High Pressure Pump
Installation VM.10345 from the upper bolt
locations.
46. Tighten the bolts (1) that secure the high-pressure
pump to 25 N·m (18 Ft. Lbs.).
47. Connect the HPFP electrical connector (2)
(Figure 152).
48. Connect the low-pressure fuel supply and return
lines (3) (Figure 155).
49. Install a NEW fuel tube (2) and hand tighten the
union nuts (1, 3). Tighten the union nuts (1,3) to 11 N·m + 75° (8 Ft. Lbs. + 75°) (Figure 166).
50. Install the nut (1) securing the fuel tube and tighten to 11 N·m (8 Ft. Lbs.) (Figure 165).
51. Install the NEW right-side fuel tubes (5, 2) to the fuel injectors No. 1 and 2 and to the fuel rail and hand
tighten the nuts. Tighten the union nuts to 11 + 75° (8 + 75°) (Figure 164).
52. Install the NEW left-side fuel tube (1) to the fuel rail and pump and hand tighten the union nuts. Tighten the
union nuts to 11 + 75° (8 + 75°) (Figures 161 and 163).
53. Install the bolt (1) securing the fuel tube and tighten to 11 N·m (8 Ft. Lbs.) (Figure 162).
54. Install the bolts (1) to the fuel line support bracket (2) and tighten to 11 N·m (8 Ft. Lbs.) (Figure 160).
55. Attach the wire harness retainer (3) (Figure 160).
56. Attach the retainers (1) securing the fuel return hose to the fuel line support bracket (Figure 159).
57. Install the fuel supply line bolt (3) and return line bolt (4) and both lines and tighten securely (Figure 158).
58. Connect the fuel return lines (1, 2) (Figure 158).
59. Connect the fuel supply (2) and return (1) lines (Figure 157).
60. Install the fuel line supply safety clip (1) (Figure 156).
61. Connect the low-pressure supply (2) and return (1) lines to the fuel injection pump (Figure 155).
62. Install the bolts (2) and the left fuel rail cover (1) and tighten securely (Figure 154).
63. Install the vent hose (1) to the left fuel rail cover (Figure 153).
Figure 174 – HPFP Bolt
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64. Connect the fuel injection pump electrical connector (2) (Figure 152).
65. Install the bolts (1) securing the sound proofing (2) to the fuel injection pump and tighten to 25 N·m (18 Ft.
Lbs.) (Figure 151).
66. Install the retainers (1) that secure the cover (2) for the high-pressure fuel pump (Figure 150).
67. Secure the retaining lock and connect the right CAC hose (2) to the turbocharger (Figure 149).
68. Install the fastener (1) securing the right Charge Air Cooler (CAC) hose and tighten securely (Figure 149).
69. Install the clean air hose (2) and tighten the clamp (1) (Figure 148).
70. Connect the crankcase breather hose.
71. Attach the CCV heater wire harness retainer (2) (Figure 147).
72. Connect the Closed Crankcase Heater Ventilation (CCV) heater wire harness connector (1) (Figure 147).
73. Install the bolt (3) securing the clean air hose (Figure 146).
74. Attach the coolant hose retainer (2) to the clean air hose (Figure 146).
75. Connect the clean air hose and tighten the clamp (1) (Figure 146).
76. Pull rearward and press down to install the engine cover (2) (Figure 145).
77. Install the two bolts (1) securing the engine cover (2) and tighten securely (Figure 145).
78. Connect the negative battery cable by installing the ground terminal nut (Figure 144).
79. Install the negative battery cable eyelet to the IBS (Figure 144).
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For vehicles with a non-contaminated fuel system, use the procedure below.
D. JL/JT Vehicles
Replace HPFP – Non-Contaminated System
WARNING: High-pressure lines deliver diesel fuel under extreme pressure from the injection pump to
the fuel injectors. This may be as high as 2000 bar (29,008 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.
WARNING: Observe the following precautions when working on fuel systems: No sparks, open flames
or smoking. Avoid inhaling and swallowing fuel. Avoid eye and skin contact with fuel. Pour fuels only
into suitable and appropriately marked containers. Wear protective clothing. Failure to observe these
precautions may result in fire, explosion, property damage, and serious or fatal injury.
WARNING: High-pressure lines deliver diesel fuel under extreme pressure from the injection pump to
the fuel injectors. This may be as high as 2000 bar (29,008 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.
WARNING: Observe the following precautions when working on fuel systems: 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: When key is cycled to the off position, fuel system pressure automatically bleeds down.
NOTE: The fuel injection pump can be replaced without having to perform the entire base engine valve
timing procedure. This procedure gives instruction on how to remove and install the new fuel injection
pump without performing the base engine timing. Do not rotate the pump shaft after removing from the
vehicle. The alignment of the pump shaft must be measured and recorded using a commercially
available degree wheel after the pump is removed and before transferring the pump gear over to the
new pump. This is done to align the pump to the same position during installation. If the base engine
valve timing must be performed as part of the repair, refer to Service Library 09 – Engine/Valve
Timing/Standard Procedure.
This procedure is for the removal and installation of the fuel injection pump only. The fuel injection pump
can be replaced without needing to perform the entire base engine valve timing procedure. This procedure
gives instruction on how to properly align the new fuel injection pump. If the base engine valve timing
must be performed, (Refer to 09 – Engine/Valve Timing/Standard Procedure). The timing of the pump is
crucial, and the gear must not be moved once the pump is removed from the timing cover.
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Battery Disconnect
1. On this dual battery system, the auxiliary battery ground cable connects to the main battery cable end
(shown in generic graphic) and grounds through the main battery ground cable connection to the body,
chassis or engine (depending on vehicle). Therefore, simply disconnecting and isolating the main battery
negative cable clamp from the main battery post will not isolate the auxiliary from the vehicle’s electrical
system. The auxiliary battery will still be grounded through its connection to the main battery negative cable
end. If both battery negative cables are not isolated, it will result in the vehicle electrical system and Power
Distribution Center (PDC) still having battery connection which can cause vehicle wiring damage or
deployment of air bags on re-connection (Figure 175). In Service Library, see 08 – Electrical / 8F – Engine
Systems / Battery System / Standard Procedure / Battery Disconnect – Dual 12 Volt Battery System.
2. Turn the ignition off. Wait five minutes to allow the main modules to go to sleep.
3. Disconnect and isolate the supplemental (auxiliary) battery negative cable from the main battery negative
cable end. This will disconnect and isolate the auxiliary battery ground.
4. The main battery ground can be disconnected by removing the main battery negative cable from the
negative battery cable end, or by disconnecting the IBS connector, loosening the negative battery clamp
nut and removing the negative battery cable end from the battery post. Either method will disconnect the
main battery. Both batteries should be disconnected from the vehicle electrical system.
5. Measure the voltage at the PDC positive battery cable connection to verify the vehicle electrical system is
powered down.
NOTE: On some vehicles a small amount of voltage may be present (typically less than
approximately 0.5 volts) due to capacitors is some modules still having voltage stored. Anything
less than 1.0 volts should be safe.
Figure 175 – Dual Battery System
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6. Remove the fuel injection pump blocker plate bolts
(2) and the fuel injection pump blocker plate (1)
from the fuel injection pump (Figure 176).
7. Remove the fuel injection pump silencer.
8. Remove the engine cover.
9. Disconnect the crankcase breather hose (3)
(Figure 177).
10. Disconnect the Closed Crankcase Ventilation
(CCV) heater wire harness connector (1) and
detach the wire harness retainer (2) (Figure 177).
11. Disconnect the clean air hose from the air cleaner
body.
Figure 176 – HPFP Blocker Plate
Figure 177 – Clean Air Hose
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12. Loosen clean air hose clamp (1) and remove the
clean air hose from the turbocharger elbow
(Figure 178).
13. Remove the vent hose from the left fuel rail cover.
14. Remove the left fuel rail cover bolts (1) and the left
fuel rail cover (2) (Figure 179).
Figure 178 – Clean Air Hose at Turbo
Figure 179 – Left Fuel Rail Cover
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15. Disconnect the low-pressure supply (2) and low
pressure return lines (1) from the fuel injection
pump (Figure 180).
16. Unscrew the union nuts (1 & 3) and remove
cylinder No. 4 fuel tube (2) and discard the fuel
tube (Figure 181).
17. Install protective caps onto the fuel injector and
fuel rail.
Figure 180 – Low Pressure Lines
Figure 181 – No. 4 Fuel Tube
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18. Unscrew the fuel tube union nut from the fuel
injection pump (3) (Figure 182).
19. Remove the fuel tube bracket nut (2) securing the
fuel tube (Figure 182).
20. Unscrew the union nut from the fuel rail (1) and
remove and discard the fuel tube (Figure 182).
21. Install protective caps onto the fuel injection pump
and fuel rail.
22. Remove the Charge Air Cooler (CAC) hose bolt
(2) securing the CAC hose to the support bracket
(Figure 183).
23. Release the retaining clip (1) and disconnect the
CAC hose from the turbocharger elbow and
position aside (Figure 183).
Figure 182 – Left Fuel Rail Supply Tube
Figure 183 – Charge Air Cooler (CAC)
Hose
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24. Loosen the right fuel rail cover nut (3), detach the
wire harness retainer (1), and remove the fuel rail
cover (2) (Figure 184).
25. Release the retaining clip (1) and disconnect the
CAC hose from the EGR air flow control valve
(Figure 185).
Figure 184 – Right Fuel Rail Cover
Figure 185 – CAC Hose
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26. Remove the fuel tube bolt (2) securing the fuel
tube (186).
27. Unscrew the union nuts (1 & 4) and remove and
discard the fuel tube (3) (Figure 186).
28. Install protective caps over the openings.
29. Disconnect the fuel quantity solenoid wire harness
connector (2) (Figure 187).
Figure 186 – Right Fuel Rail Supply
Tube
Figure 187 – Fuel Quantity Solenoid
Wire Harness Connector
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30. Remove the upper bolts (1) from the highpressure
pump (2) (Figure 188). Using Tool, High
Pressure Pump Installation VM.10345 Install the
studs in the upper locations.
31. Remove the lower bolt (1) from the HPFP (2) and
slide the pump away from the engine as far as
possible (Figure 189).
NOTE: The timing of the pump is crucial, and
the gear must not be moved once the pump is
removed from the timing cover.
32. While holding the pump in place, remove the VM.
10345 pins, then remove the pump from the
vehicle.
NOTE: The fuel injection pump needs to be
timed using a commercially available degree
wheel.
Figure 188 – HPFP Upper Bolts
Figure 189 – HPFP Lower Bolt
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33. Install the degree wheel onto the fuel injection
pump with the zero at the fuel quantity solenoid
then mark the location of the hole in the gear on
the degree wheel (Figure 190).
34. Using a commercially available spanner wrench
such as Blue Point APS35IB, Snap-on APS351C
or equivalent to hold fuel injection pump gear.
Remove the fuel injection pump gear nut
(Figure 191).
Figure 190 – Installing a Printed Paper
Degree Wheel from the Internet
Figure 191 – Gear Nut Removal
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35. The use of Puller 1023 or a commercially
available gear puller is required to remove the fuel
injection pump gear (2) (Figure 192).
WARNING: High-pressure lines deliver diesel fuel under extreme pressure from the injection pump
to the fuel injectors. This may be as high as 2000 bar (29,008 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.
CAUTION: Do Not Force the high-pressure pump into the right timing cover or attempt to seat it by
drawing it in with the bolts. The pump gear must be properly aligned with the drive gear on the
camshaft before the high-pressure pump will seat on the cylinder head mounting surface. Failure to
properly align drive gears will damage the high-pressure pump or camshaft drive gear.
NOTE: The high-pressure pump needs to be timed before it can be installed. Use a commercially
available degree wheel to time the high-pressure pump.
36. If removed, install the gear (2) and (1) nut onto the fuel injection pump (3) and tighten the nut finger tight
(Figure 192).
Figure 192 – Swapping the Drive Gear
on the HPFP
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37. Using a commercially available spanner wrench
such as Blue Point APS35IB, Snap-on APS351C
or equivalent (2) and tighten the fuel injection
pump gear nut (1) to 50 N·m (37 Ft. Lbs.)
(Figure 193).
38. Install the degree wheel with the zero aligned with
the fuel quantity solenoid and rotate the pump
shaft so that the hole aligns with the reference
mark on the degree wheel referenced during the
removal (Figure 194).
Figure 193 – Gear Nut Removal
Figure 194 – Installing a Printed Paper
Degree Wheel from the Internet
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39. Install a NEW O-ring (1) to the high-pressure fuel
injection pump (Figure 195).
40. Install the pump to the engine using the pins as a
guide. Install the lower fuel injection pump bolt (1)
and hand tighten the bolt (Figure 196).
41. Remove the Tool, High Pressure Pump
Installation VM.10345 from the upper bolt
locations.
Figure 195 – O-ring
Figure 196 – HPFP Lower Bolt
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42. Install the high-pressure fuel injection pump upper bolts (Figure 188).
43. Tighten the high-pressure fuel injection pump upper and lower bolts to 25 N·m (18 Ft. Lbs.).
44. Connect the fuel quantity solenoid wire harness connector (2) (Figure 187).
45. Connect the low-pressure fuel supply/return lines (4) (Figure 187).
46. Remove the protective caps over the openings.
NOTE: Fuel tubes are a onetime only use and must be replaced anytime they have been removed.
47. Start the union nuts (1 & 4) on the NEW fuel tube (3). Tighten the union nuts (1,3) to 11 N·m + 75° (8 Ft.
Lbs. + 75°) (Figure 186).
48. Install the fuel tube bolt (2) securing the fuel tube and tighten securely (186).
49. Connect the CAC hose to the EGR air flow control valve and secure the retaining clip (1) (Figure 185).
50. Install the fuel rail cover (2), attach the wire harness retainer (1), and tighten the right fuel rail cover nut (3)
to 5 N·m (44 In. Lbs.) (Figure 184).
51. Install the Charge Air Cooler (CAC) hose bolt (2) securing the CAC hose to the support bracket and tighten
to 11 N·m (8 Ft. Lbs.) (Figure 183).
52. Attach the retaining clip (1) and connect the CAC hose from the turbocharger elbow (Figure 183).
53. Remove protective caps from the fuel injection pump and fuel rail.
54. Install the NEW fuel tube. Hand tighten the union nuts to the fuel rail (1) and tighten to 11 N·m + 75° (8 Ft.
Lbs. + 75°) (Figure 182).
55. Install the fuel tube bracket nut (2) securing the fuel tube and tighten to 8 N·m (71 In. Lbs.) (Figure 182).
56. Hand tighten the fuel tube union nut to the fuel injection pump (3) and tighten to 11 N·m + 75° (8 Ft. Lbs. +
75°) (Figure 182).
57. Remove protective caps from the fuel injector and fuel rail (Figure 181).
58. Hand tighten the union nuts (1 & 3) and install a NEW cylinder No. 4 fuel tube (2). Tighten the union nuts to
11 N·m + 75° (8 Ft. Lbs. + 75°) (Figure 181).
59. Install the left fuel rail cover (2) and bolts (1) and tighten to 5 N·m (44 In. Lbs.) (Figure 179).
60. Install the vent hose to the left fuel rail cover.
61. Install the clean air hose to the turbocharger elbow and securely tighten the clean air hose clamp (1)
(Figure 178).
62. Connect the clean air hose to the air cleaner body (Figure 177).
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63. Connect the Closed Crankcase Ventilation (CCV) heater wire harness connector (1) and attach the wire
harness retainer (2) (Figure 177).
64. Connect the crankcase breather hose (3) (Figure 177).
65. Install the engine cover.
66. Install the fuel injection pump silencer.
67. Install the fuel injection pump blocker plate (1) to the fuel injection pump. Install the fuel injection pump
blocker plate bolts (2) and tighten 25 N·m (18 Ft. Lbs.) (Figure 176).
68. Connect the negative battery cables. In Service Library, see 08 – Electrical / 8F – Engine Systems / Battery
System / Standard Procedure / Battery Disconnect – Dual 12 Volt Battery System.
69. Start engine and check for leaks.
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For all platforms above (DT, JL, JT) and both contaminated and non-contaminated systems, complete step E.
Install the Authorized Modifications Label.
E. Install the Authorized Modifications Label:
1. Type or print (with a ballpoint pen) the necessary
information shown in (Figure 197) onto the
authorized modifications Label.
2. Remove the paper backing from the clear film on the
front of the authorized modifications label then
carefully apply the clear film over the front of the
authorized modifications label (Figure 198).
Figure 198 – Apply Clear Film
CLEAR FILM
PAPER
BACKING
LABEL
Figure 197 – Authorized Modifications Label
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NOTE: The Authorized Modifications Label should be located near the Vehicle Emission Control Information
(VECI) label (Figure 199).
3. Locate the VECI label on the underside of the engine
compartment hood (Figure 199).
NOTE: For vehicles missing a VECI label, locate
a flat protected area on the underside of the hood
to apply the authorized modifications label.
4. Clean the surface near the VECI label with isopropyl
alcohol or equivalent and a soft cloth.
5. Remove the authorized modifications label from its paper backing.
6. Apply the authorized modifications label next to the VECI label (Figure 199).
7. Firmly press and smooth the authorized modifications label to ensure good adhesion.
8. Close the engine compartment hood.
9. Complete the Proof of Correction Form for California Residents, Section F.
Figure 199 – Apply Authorized Modifications Label
Near VECI Label
(Specific Vehicle May Look Different)
VECI LABEL
AUTHORIZED MODIFICATIONS LABEL
SAFETY RECALL – NORTH AMERICA
High Pressure Fuel Pump
Reference: 01A / NHTSA 23V-263
FCA US LLC
_________________________________________________________
Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any intervention.
Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer.
Reproduction forbidden without the written agreement of STELLANTIS Group. (DJT)
124/125
F. Complete Proof of Correction Form for California Residents:
This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement
Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply
it to vehicle owners residing in the state of California for proof that this recall has been performed when
they renew the vehicle registration.
Process Steps to obtain the California Proof of Correction form:
a. Access the “DealerCONNECT” website.
b. Select the “Service” tab.
c. Under the “Publications” heading, select the “ePublishing” link.
d. Sign in using your Dealer Code and Password.
e. Select the “Proof of Correction form”.
G. Owner’s Manual Addendum and Tip Card:
From Campaign kit CSFP01A1AA, place the Owner’s Manual Addendum in the glovebox with the Owner’s Manual.
Place the Tip Card in a conspicuous location that will be visible to the drive so that they will review it. Suggestions
would be the top of the instrument panel, in front of the instrument cluster, etc. Please review the information on the
card with the owner when the vehicle is returned to them.
SAFETY RECALL – NORTH AMERICA
High Pressure Fuel Pump
Reference: 01A / NHTSA 23V-263
FCA US LLC
_________________________________________________________
Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any intervention.
Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer.
Reproduction forbidden without the written agreement of STELLANTIS Group. (DJT)
125/125
H. Fuel Door Label:
NOTE: Do not apply the label over an existing label. Apply the label on a flat surface on the inside of the
fuel door. For example, on the top of the fuel door hinge (Figure 201).
From Campaign kit CSFP01A1AA, install the fuel door
decal.
1. Open the fuel door.
2. Clean the top surface of the hinge with isopropyl
alcohol or equivalent and a soft cloth. Repeat as
needed until the soft cloth comes off the surface
clean.
3. Remove the fuel door label from its paper backing.
4. Apply the fuel door label (Figure 200) to the top of
the fuel door hinge (Figure 201).
5. Firmly press and smooth the fuel door label to
ensure good adhesion.
6. Close the fuel door.
Figure 200 – Fuel Door Label
Figure 201 – Fuel Door Hinge Location
DECAL LOCATION
This notice applies to your vehicle,
01A/NHTSA 23V-263
YOUR SCHEDULING OPTIONS
1. RECOMMENDED OPTION
Call your authorized Chrysler /
Dodge / Jeep® / RAM Dealership.
2. Call the FCA Recall Assistance
Center at 1-800-853-1403. An
agent can confirm part availability
and help schedule an appointment
3. Visit recalls.mopar.com, scan the
QR code below, or download the
Mopar Owner’s Companion App.
Get access to recall notifications, locate
your nearest dealer, and more through
this website or Mopar Owner’s
Companion App. You will be asked to
provide your Vehicle Identification
Number (VIN) to protect and verify
your identity. The last eight characters
of your VIN are provided above.
DEALERSHIP INSTRUCTIONS
Please reference Safety Recall 01A.
IMPORTANT SAFETY RECALL
High Pressure Fuel Pump
Dear [Name],
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.
FCA US LLC, has decided that a defect, which relates to motor vehicle safety, exists in certain
[2022 through 2023 Model Year (DT) Ram 1500 Pickups and 2021 through 2023 Model Year
(JL) Jeep® Wrangler and (JT) Gladiator] vehicles.
It is extremely important to take steps now to repair your vehicle to ensure the safety of you and
your passengers.
WHY DOES MY VEHICLE NEED REPAIRS?
The High-Pressure Fuel Pump (HPFP) on your vehicle [1] may fail prematurely. A HPFP
failure may introduce internally failed component debris into the fuel system potentially causing
fuel starvation. Vehicle occupants may notice a Malfunction Indicator Lamp, service Electronic
Throttle Control indicator, a fuel leak at the HPFP, or excessive noise from the HPFP. Fuel
starvation may result in an unexpected loss of motive power, which can cause a vehicle
crash without prior warning.
HOW DO I RESOLVE THIS IMPORTANT SAFETY ISSUE?
FCA US will repair your vehicle [2] free of charge (parts and labor). To do this, your dealer
will replace the HPFP, inspect and, if necessary, replace additional fuel system components. The
estimated repair time is estimated to be between 2 hours to 7 hours depending on the repair
needed. In addition, your dealer will require your vehicle for proper check-in, preparation, and
check-out during your visit, which may require more time. Your time is important to us, so
we recommend that you schedule a service appointment to minimize your inconvenience. Please
bring this letter with you to your dealership.
TO SCHEDULE YOUR FREE REPAIR,
CALL YOUR CHRYSLER, DODGE, JEEP OR RAM DEALER TODAY
CALIFORNIA RESIDENTS
The State of California requires the completion of emission recall repairs prior to vehicle
registration renewal. Your dealer will provide you with a Vehicle Emission Recall Proof of
Correction Form after the Safety Recall service is performed. Be sure to save this form since
the California Department of Motor Vehicles may require that you supply it as proof that the
Safety Recall has been performed.
In order to ensure your full protection under the emissions warranty provisions, it is
recommended that you have your (vehicle or engine) serviced as soon as possible. Failure to do
so could be determined as lack of proper maintenance of your (vehicle or engine).
WHAT IF I ALREADY PAID TO HAVE THIS REPAIR COMPLETED?
If you have already experienced this specific condition and have paid to have it repaired, you
may visit www.fcarecallreimbursement.com to submit your reimbursement request online. [3]
Once we receive and verify the required documents, reimbursement will be sent to you within
60 days. If you have had previous repairs performed and/or already received reimbursement,
you may still need to have the recall repair performed.
We apologize for any inconvenience, but are sincerely concerned about your safety. Thank you
for your attention to this important matter.
Customer Assistance/Field Operations
FCA US LLC
[Model Year and Model]
VIN XXXXXXXXXXXXXXXXX
LOGO
VEHICLE PICTURE
QR Code
[1] If you no longer own this vehicle, please help us update our records. Call the FCA Recall Assistance Center at 1-800-853-1403 to update your information.
[2] If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway
Traffic Safety Administration, 1200 New Jersey Ave., S.E., Washington, DC 20590, or you can call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-
9153), or go to safercar.gov.
[3] You can also mail in your original receipts and proof of payment to the following address for reimbursement consideration: FCA Customer Assistance, P.O. Box 21-8004,
Auburn Hills, MI 48321-8007, Attention: Recall Reimbursement.
Note to lessors receiving this recall notice: Federal regulation requires that you forward this recall notice to the lessee within 10 days.
Mr. Mrs. Customer
1234 Main Street
Hometown, MI 48371

**************************************************************************************************************

This notice applies to your vehicle,
01A/NHTSA 23V-263
YOUR SCHEDULING OPTIONS
1. RECOMMENDED OPTION
Call your authorized Chrysler / Dodge / Jeep® / RAM Dealership.
2. Call the FCA Recall Assistance Center at 1-800-853-1403. An agent can confirm part availability and help schedule an appointment
3. Visit recalls.mopar.com, scan the QR code below, or download the Mopar Owner’s Companion App.
Get access to recall notifications, locate your nearest dealer, and more through this website or Mopar Owner’s Companion App. You will be asked to provide your Vehicle Identification Number (VIN) to protect and verify your identity. The last eight characters of your VIN are provided above.
DEALERSHIP INSTRUCTIONS
Please reference Safety Recall 01A.
IMPORTANT SAFETY RECALL
High Pressure Fuel Pump
Dear [Name],
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.
FCA US LLC, has decided that a defect, which relates to motor vehicle safety, exists in certain [2022 through 2023 Model Year (DT) Ram 1500 Pickups and 2021 through 2023 Model Year (JL) Jeep® Wrangler and (JT) Gladiator] vehicles.
It is extremely important to take steps now to repair your vehicle to ensure the safety of you and your passengers.
WHY DOES MY VEHICLE NEED REPAIRS?
The High-Pressure Fuel Pump (HPFP) on your vehicle [1] may fail prematurely. A HPFP failure may introduce internally failed component debris into the fuel system potentially causing fuel starvation. Vehicle occupants may notice a Malfunction Indicator Lamp, service Electronic Throttle Control indicator, a fuel leak at the HPFP, or excessive noise from the HPFP. Fuel starvation may result in an unexpected loss of motive power, which can cause a vehicle crash without prior warning.
HOW DO I RESOLVE THIS IMPORTANT SAFETY ISSUE? FCA US will repair your vehicle [2] free of charge (parts and labor). To do this, your dealer will replace the HPFP, inspect and, if necessary, replace additional fuel system components. The estimated repair time is estimated to be between 2 hours to 7 hours depending on the repair needed. In addition, your dealer will require your vehicle for proper check-in, preparation, and check-out during your visit, which may require more time. Your time is important to us, so we recommend that you schedule a service appointment to minimize your inconvenience. Please bring this letter with you to your dealership.
TO SCHEDULE YOUR FREE REPAIR,
CALL YOUR CHRYSLER, DODGE, JEEP OR RAM DEALER TODAY
CALIFORNIA RESIDENTS
The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the Safety Recall service is performed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof that the Safety Recall has been performed.
In order to ensure your full protection under the emissions warranty provisions, it is recommended that you have your (vehicle or engine) serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your (vehicle or engine).
WHAT IF I ALREADY PAID TO HAVE THIS REPAIR COMPLETED?
If you have already experienced this specific condition and have paid to have it repaired, you may visit www.fcarecallreimbursement.com to submit your reimbursement request online. [3] Once we receive and verify the required documents, reimbursement will be sent to you within 60 days. If you have had previous repairs performed and/or already received reimbursement, you may still need to have the recall repair performed.
We apologize for any inconvenience, but are sincerely concerned about your safety. Thank you for your attention to this important matter.
Customer Assistance/Field Operations
FCA US LLC
[Model Year and Model]
VIN XXXXXXXXXXXXXXXXX
LOGO
VEHICLE PICTURE
QR Code
[1] If you no longer own this vehicle, please help us update our records. Call the FCA Recall Assistance Center at 1-800-853-1403 to update your information.
[2] If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway
Traffic Safety Administration, 1200 New Jersey Ave., S.E., Washington, DC 20590, or you can call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-
9153), or go to safercar.gov.
[3] You can also mail in your original receipts and proof of payment to the following address for reimbursement consideration: FCA Customer Assistance, P.O. Box 21-8004,
Auburn Hills, MI 48321-8007, Attention: Recall Reimbursement.
Note to lessors receiving this recall notice: Federal regulation requires that you forward this recall notice to the lessee within 10 days.
Mr. Mrs. Customer
1234 Main Street
Hometown, MI 48371

**************************************************************************************************************

This notice applies to your vehicle,
01A/NHTSA 23V-263
YOUR SCHEDULING OPTIONS
1. RECOMMENDED OPTION
Call your authorized Chrysler / Dodge / Jeep® / RAM Dealership.
2. Call the FCA Recall Assistance Center at 1-800-853-1403. An agent can confirm part availability and help schedule an appointment.
3. Visit recalls.mopar.com, scan the QR code below, or download the Mopar Owner’s Companion App.
Get access to recall notifications, locate your nearest dealer, and more through this website or Mopar Owner’s Companion App. You will be asked to provide your Vehicle Identification Number (VIN) to protect and verify your identity. The last eight characters of your VIN are provided above.
DEALERSHIP INSTRUCTIONS
Please reference Safety Recall 01A.
IMPORTANT SAFETY RECALL
High Pressure Fuel Pump
Dear [Name],
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.
FCA US LLC, has decided that a defect, which relates to motor vehicle safety, exists in certain [2021 through 2023 Model Year (JL) Jeep® Wrangler and (JT) Gladiator] vehicles.
It is extremely important to take steps now to repair your vehicle to ensure the safety of you and your passengers.
WHY DOES MY VEHICLE NEED REPAIRS?
The High-Pressure Fuel Pump (HPFP) on your vehicle [1] may fail prematurely. A HPFP failure may introduce internally failed component debris into the fuel system potentially causing fuel starvation. Fuel starvation may result in an unexpected loss of motive power, which can cause a vehicle crash without prior warning.
HOW DO I RESOLVE THIS IMPORTANT SAFETY ISSUE? FCA US will repair your vehicle [2] free of charge (parts and labor). To do this, your dealer will replace the HPFP, inspect and, if necessary, replace additional fuel system components. The estimated repair time is estimated to be between 2 hours to 7 hours depending on the repair needed. In addition, your dealer will require your vehicle for proper check-in, preparation, and check-out during your visit, which may require more time. Your time is important to us, so we recommend that you schedule a service appointment to minimize your inconvenience. Please bring this letter with you to your dealership.
TO SCHEDULE YOUR FREE REPAIR,
CALL YOUR CHRYSLER, DODGE, JEEP OR RAM DEALER TODAY
CALIFORNIA RESIDENTS
The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the Safety Recall service is performed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof that the Safety Recall has been performed.
In order to ensure your full protection under the emissions warranty provisions, it is recommended that you have your (vehicle or engine) serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your (vehicle or engine).
WHAT IF I ALREADY PAID TO HAVE THIS REPAIR COMPLETED?
If you have already experienced this specific condition and have paid to have it repaired, you may visit www.fcarecallreimbursement.com to submit your reimbursement request online. [3] Once we receive and verify the required documents, reimbursement will be sent to you within 60 days. If you have had previous repairs performed and/or already received reimbursement, you may still need to have the recall repair performed.
We apologize for any inconvenience, but are sincerely concerned about your safety. Thank you for your attention to this important matter.
Customer Assistance/Field Operations
FCA US LLC
[Model Year and Model]
VIN XXXXXXXXXXXXXXXXX
LOGO
VEHICLE PICTURE
QR Code
[1] If you no longer own this vehicle, please help us update our records. Call the FCA Recall Assistance Center at 1-800-853-1403 to update your information.
[2] If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway
Traffic Safety Administration, 1200 New Jersey Ave., S.E., Washington, DC 20590, or you can call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-
9153), or go to safercar.gov.
[3] You can also mail in your original receipts and proof of payment to the following address for reimbursement consideration: FCA Customer Assistance, P.O. Box 21-8004,
Auburn Hills, MI 48321-8007, Attention: Recall Reimbursement.
Note to lessors receiving this recall notice: Federal regulation requires that you forward this recall notice to the lessee within 10 days.
Mr. Mrs. Customer
1234 Main Street
Hometown, MI 48371

**************************************************************************************************************

04/20/2023
_____________________________________________________________________
New Safety Recall Advanced Communication – 01A
FCA US LLC (FCA US) has announced a safety recall on certain 2022 through 2023
Model Year (DT) Ram 1500 Pickups and 2021 through 2023 Model Year (JL) Jeep®
Wrangler and (JT) Gladiator vehicles equipped with a 3.0L engines.
VINs identified as being involved in this campaign are currently live and searchable.
Stop sale is in effect for the above-identified vehicles.
Vehicles impacted by a stop sale are eligible for reimbursement allowance through the
Recall Floorplan Reimbursement Policy (RFPRP), which can be requested upon recall
claim submission.
REASON FOR THIS SAFETY RECALL
Some of the above vehicles may have been built with a High Pressure Fuel Pump
(“HPFP”) that could fail prematurely.
A HPFP failure may introduce internally failed component debris into the fuel system
potentially causing fuel starvation. Fuel starvation may result in an unexpected loss of
motive power, which can cause a vehicle crash without prior warning.
SERVICE ACTION
FCA US will conduct a voluntary safety recall to replace the HPFP, and inspect and, if
necessary, replace additional fuel system components. The remedy for this condition is
not currently available. Dealers will be notified of the launch of this safety recall by way
of established communication methods. This recall is estimated to launch in 3rd
Quarter of 2023.
We ask that you please take the time to ensure that your personnel are aware of this
communication and are prepared to execute a customer friendly process for inquiries
regarding involved vehicles.
Customer Services Field Operations
FCA US LLC
IMPORTANT: Some of the involved vehicles may be in dealer new vehicle
inventory. Federal law requires you to complete this recall service on these
vehicles before retail delivery. Violation of this requirement by a dealer could
result in a civil penalty of up to $21,000 per vehicle. Involved vehicles can be
determined by using the VIP inquiry process.
This notice applies to your vehicle,
01A/NHTSA 23V-263
YOUR SCHEDULING OPTIONS
1. Visit recalls.mopar.com to sign up
for email or SMS notifications for
when remedy parts become
available. You will be asked to
provide your Vehicle Identification
Number (VIN), provided above
2. Scan below using your smartphone
or tablet to sign up to be notified
when remedy parts become
available
3. Wait for FCA US to contact you
again, by mail, with a follow-up
recall notice when remedy parts are
available
4. Call the FCA Recall Assistance
Center at 1-800-853-1403. An
agent can sign you up to be notified
when remedy parts become
available, or answer any other
questions you may have
DEALERSHIP INSTRUCTIONS
Please reference Safety Recall 01A.
IMPORTANT SAFETY RECALL
High Pressure Fuel Pump
Dear [Name],
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety
Act.
FCA US LLC, has decided that a defect, which relates to motor vehicle safety, exists in certain
[2022 through 2023 Model Year (DT) Ram 1500 Pickups and 2021 through 2023 Model Year
(JL) Jeep® Wrangler and (JT) Gladiator] vehicles.
WHY DOES MY VEHICLE NEED REPAIRS?
The High Pressure Fuel Pump (HPFP) on your vehicle [1] may fail prematurely. A HPFP
failure may introduce internally failed component debris into the fuel system potentially
causing fuel starvation. Fuel starvation may result in an unexpected loss of motive power,
which can cause a vehicle crash without prior warning.
HOW DO I RESOLVE THIS IMPORTANT SAFETY ISSUE?
The remedy for this condition is not currently available. We are making every effort to
finalize the remedy, and will service your vehicle free of charge (parts and labor) when the
remedy is available.
FCA US will contact you again, by mail, with a follow-up recall notice when the remedy is
available. Once you receive your follow-up notice, simply contact your Chrysler, Jeep®,
Dodge or RAM dealer right away to schedule a service appointment [2]. Additional options for
your next steps are included on the left side of this notification. We appreciate your patience.
WHAT IF I ALREADY PAID TO HAVE THIS REPAIR COMPLETED?
If you have already experienced this specific condition and have paid to have it repaired, you
may visit www.fcarecallreimbursement.com to submit your reimbursement request online [3].
Once we receive and verify the required documents, reimbursement will be sent to you within
60 days. If you have had previous repairs performed and/or already received reimbursement,
you may still need to have the recall repair performed.
We apologize for any inconvenience, but are sincerely concerned about your safety. Thank
you for your attention to this important matter.
Customer Assistance/Field Operations
FCA US LLC
[Model Year and Model]
VIN XXXXXXXXXXXXXXXXX
VEHICLE PICTURE
LOGO
QR Code
[1] If you no longer own this vehicle, please help us update our records. Call the FCA Recall Assistance Center at 1-800-853-1403 to update your information.
[2] If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National
Highway Traffic Safety Administration, 1200 New Jersey Ave., S.E., Washington, DC 20590, or you can call the toll-free Vehicle Safety Hotline at 1-888-327-4236
(TTY 1-800-424-9153), or go to safercar.gov.
[3] You can also mail in your original receipts and proof of payment to the following address for reimbursement consideration: FCA Customer Assistance, P.O. Box 21-
8004, Auburn Hills, MI 48321-8007, Attention: Recall Reimbursement.
Note to lessors receiving this recall notice: Federal regulation requires that you forward this recall notice to the lessee within 10 days.
Mr. Mrs. Customer
1234 Main Street
Hometown, MI 48371

**************************************************************************************************************

04/14/2023
_____________________________________________________________________
New Safety Recall Advanced Communication – 01A
FCA US LLC (FCA US) has announced a safety recall on certain 2022 through 2023 Model Year (DT) Ram 1500 Pickups and 2021 through 2023 Model Year (JL) Jeep® Wrangler and (JT) Gladiator vehicles equipped with a 3.0L engines.
REASON FOR THIS SAFETY RECALL
Some of the above vehicles may have been built with a High Pressure Fuel Pump (“HPFP”) that could fail prematurely.
A HPFP failure may introduce internally failed component debris into the fuel system potentially causing fuel starvation. Fuel starvation may result in an unexpected loss of motive power, which can cause a vehicle crash without prior warning.
SERVICE ACTION
FCA US will conduct a voluntary safety recall to replace the HPFP, and inspect and, if necessary, replace additional fuel system components. The remedy for this condition is not currently available. Dealers will be notified of the launch of this safety recall by way of established communication methods. This recall is estimated to launch in 3rd Quarter of 2023.
We ask that you please take the time to ensure that your personnel are aware of this communication and are prepared to execute a customer friendly process for inquiries regarding involved vehicles.
Customer Services Field Operations
FCA US LLC

**************************************************************************************************************

04/20/2023
_____________________________________________________________________
New Safety Recall Advanced Communication – 01A
FCA US LLC (FCA US) has announced a safety recall on certain 2022 through 2023 Model Year (DT) Ram 1500 Pickups and 2021 through 2023 Model Year (JL) Jeep® Wrangler and (JT) Gladiator vehicles equipped with a 3.0L engines.
VINs identified as being involved in this campaign are currently live and searchable. Stop sale is in effect for the above-identified vehicles.
Vehicles impacted by a stop sale are eligible for reimbursement allowance through the Recall Floorplan Reimbursement Policy (RFPRP), which can be requested upon recall claim submission.
REASON FOR THIS SAFETY RECALL
Some of the above vehicles may have been built with a High Pressure Fuel Pump (“HPFP”) that could fail prematurely.
A HPFP failure may introduce internally failed component debris into the fuel system potentially causing fuel starvation. Fuel starvation may result in an unexpected loss of motive power, which can cause a vehicle crash without prior warning.
SERVICE ACTION
FCA US will conduct a voluntary safety recall to replace the HPFP, and inspect and, if necessary, replace additional fuel system components. The remedy for this condition is not currently available. Dealers will be notified of the launch of this safety recall by way of established communication methods. This recall is estimated to launch in 3rd Quarter of 2023.
We ask that you please take the time to ensure that your personnel are aware of this communication and are prepared to execute a customer friendly process for inquiries regarding involved vehicles.
Customer Services Field Operations
FCA US LLC
IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Violation of this requirement by a dealer could result in a civil penalty of up to $21,000 per vehicle. Involved vehicles can be determined by using the VIP inquiry process.

**************************************************************************************************************

RECALL 01A, Z46, OR Z96 – 3.0L ENGINE
HIGH-PRESSURE FUEL PUMP REPAIR
JULY 2023
If you have customer in for service with a 3.0L engine affected by recall 01A, Z46, or Z96, and the repair requires a high-pressure
fuel pump, it is appropriate to use current service parts in the repair.
PN 68501449AA (old HPFP) has superseded to PN 68631088AA (new). Additionally, some orders for the new part number (PN
68631088AA) have been filled using the campaign kit PN CSSMZ461AA. If you have received PN CSSMZ461AA it can be used as a
current service part.
The customer should NOT be charged for the repair. Submit a warranty claim in RA status with the proper details for approval and
payment.
If you have any questions, please reach out to your tech advisor/area manager directly.

**************************************************************************************************************

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-263
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Chrysler (FCA US, LLC) AUG 15, 2023 NHTSA Recall No. : 23V-263 Manufacturer Recall No. : 01A Manufacturer Information :
Manufacturer Name : Chrysler (FCA US, LLC) Address : 800 Chrysler Drive
CIMS 482-00-91 Auburn Hills MI 48326-2757
Company phone : 1-800-853-1403
Population :
Number of potentially involved : 45,832 Estimated percentage with defect : 1 %
Vehicle Information : Vehicle 1 : 2021-2023 Jeep Wrangler Vehicle Type : Body Style : SUV Power Train : NR
Descriptive Information : Some 2021-2023 MY Jeep Wrangler vehicles equipped with a 3.0L diesel engine may have been built with a high pressure fuel pump (“HPFP”) that could fail prematurely.
The suspect period began on November 2, 2021, when 3.0L Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on January 13, 2023, when 3.0L Diesel engine vehicle production ended. The suspect period was determined using field data and engineering change records. Similar vehicles not included in the recall population are not equipped with the 3.0L Diesel engine, were included in FCA US LLC (“FCA US”) Recall ID Z96 (NHTSA Recall ID 22V-767), or were produced before the suspect period. The total affected vehicles for this model is 11,486.
Production Dates : NOV 02, 2021 – JAN 13, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-263 Page 2 Vehicle 2 : 2022-2023 Ram 1500 Vehicle Type : Body Style : PICKUP TRUCK Power Train : NR
Descriptive Information : Some 2022-2023 MY Ram 1500 vehicles equipped with a 3.0L diesel engine may have been built with a HPFP that could fail prematurely. The suspect period began on October 5, 2021, when 3.0L Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on March 23, 2023, when 3.0L Diesel engine vehicle production ended. The suspect period was determined using field data and engineering change records. Similar vehicles not included in the recall population are not equipped with the 3.0L Diesel engine, were included in FCA US Recall ID Z96 (NHTSA Recall ID 22V-767), or were produced before the suspect period. The total affected vehicles for this model is 26,671. Production Dates : OCT 05, 2021 – MAR 23, 2023
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 3 : 2021-2023 Jeep Gladiator Vehicle Type : Body Style : PICKUP TRUCK Power Train : NR
Descriptive Information : Some 2021-2023 MY Jeep Gladiator vehicles equipped with a 3.0L diesel engine may have been built with a HPFP that could fail prematurely. The suspect period began on October 14, 2021, when 3.0L Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on May 5, 2023, when 3.0L Diesel engine vehicle production ended. The suspect period was determined using field data and engineering change records. Similar vehicles not included in the recall population are not equipped with the 3.0L Diesel engine, or were produced before or after the suspect period or were included in FCA US Recall ID Z96 (NHTSA Recall ID 22V-767), or were produced before or after the suspect period. The total affected vehicles for this model is 7,675. Production Dates : OCT 14, 2021 – MAY 05, 2023
VIN Range 1 : Begin : NR End : NR Not sequential The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-263 Page 3 Description of Defect :
Description of the Defect : A HPFP failure may introduce internally failed component debris into the fuel system potentially causing fuel starvation.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : Fuel starvation may result in an unexpected loss of motive power, which can cause a vehicle crash without prior warning.
Description of the Cause : NR Identification of Any Warning
that can Occur : Vehicle occupants may notice a Malfunction Indicator Lamp, service Electronic Throttle Control indicator, a fuel leak at the HPFP, or excessive noise from the HPFP. Involved Components : Component Name 1 : High Pressure Fuel Pump Component Description : High Pressure Fuel Pump Component Part Number : 68501449AA Supplier Identification : Component Manufacturer
Name : Robert Bosch GmbH Address : Robert-Bosch-Platz 1
Gerlingen-Schillerhhe Foreign States 70839
Country : Germany Chronology :
• On February 9, 2022, the FCA US Technical Safety and Regulatory Compliance (“TSRC”) organization opened an investigation into 2021-2023 MY Jeep Wrangler, 2021-2023 MY Jeep Gladiator, and 2022-2023 MY Ram 1500 vehicles for potential premature high pressure fuel pump failures in vehicles equipped with the 3.0L diesel engine which may result in a stall. • From February 2022, through March 2023, FCA US TSRC conducted an analysis of stall patterns and vehicle history, determined that the affected vehicles were equipped with the Bosch CP4.2 high pressure fuel pump, and determined that the high pressure fuel pump was the origin of the stalls. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-263 Page 4 • As of March 30, 2023, FCA US is aware of seven customer assistance records, 126 warranty claims, eight field reports, and three other service records potentially related to this issue for all markets with dates of receipt ranging from April 14, 2022 to March 9, 2023. • As of March 30, 2023, FCA US is not aware of any accidents or injuries potentially related to this issue for all markets. • On April 6, 2023, FCA US determined, through the Vehicle Regulations Committee, to conduct a voluntary safety recall of the affected vehicles. Description of Remedy :
Description of Remedy Program : FCA US will conduct a voluntary safety recall on all affected vehicles to
replace the HPFP, and inspect and, if necessary, replace additional fuel system components. FCA US has a longstanding policy and practice of reimbursing owners who have incurred the cost of repairing a problem that subsequently becomes the subject of a field action. To ensure consistency, FCA US, as part of the owner letter, will request that customers send the original receipt and/or other adequate proof of payment to the company for confirmation of the expense. How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production : The remedy component is a HPFP with improved durability. NR Recall Schedule :
Description of Recall Schedule : **08/15/2023: FCA US will notify dealers and begin notifying owners
with the Final Owner letter, in phases, starting with the Jeep Wrangler, and Jeep Gladiator, on or about 10/24/2023.
FCA US will notify dealers and begin notifying owners with the Final Owner letter, of the Ram 1500, on or about 11/21/2023. **06/01/2023: FCA US will notify dealers and begin notifying owners with the Final Owner Letter on or about 08/24/2023. **04/13/2023: FCA US will notify dealers and begin notifying owners on or about 06/02/2023. Planned Dealer Notification Date : JUN 02, 2023 – JUN 02, 2023 The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-263
Page 5
The information contained in this report was submitted pursuant to 49 CFR §573 Planned Owner Notification Date : JUN 02, 2023 – JUN 02, 2023
* NR – Not Reported

**************************************************************************************************************

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-263
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Chrysler (FCA US, LLC) JUN 01, 2023 NHTSA Recall No. : 23V-263 Manufacturer Recall No. : 01A Manufacturer Information :
Manufacturer Name : Chrysler (FCA US, LLC) Address : 800 Chrysler Drive
CIMS 482-00-91 Auburn Hills MI 48326-2757
Company phone : 1-800-853-1403
Population :
Number of potentially involved : 45,832 Estimated percentage with defect : 1 %
Vehicle Information : Vehicle 1 : 2021-2023 Jeep Wrangler Vehicle Type : Body Style : SUV Power Train : NR
Descriptive Information : Some 2021-2023 MY Jeep Wrangler vehicles equipped with a 3.0L diesel engine may have been built with a high pressure fuel pump (“HPFP”) that could fail prematurely.
The suspect period began on November 2, 2021, when 3.0L Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on January 13, 2023, when 3.0L Diesel engine vehicle production ended. The suspect period was determined using field data and engineering change records. Similar vehicles not included in the recall population are not equipped with the 3.0L Diesel engine, were included in FCA US LLC (“FCA US”) Recall ID Z96 (NHTSA Recall ID 22V-767), or were produced before the suspect period. The total affected vehicles for this model is 11,486.
Production Dates : NOV 02, 2021 – JAN 13, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-263 Page 2 Vehicle 2 : 2021-2023 Jeep Gladiator Vehicle Type : Body Style : PICKUP TRUCK Power Train : NR
Descriptive Information : Some 2021-2023 MY Jeep Gladiator vehicles equipped with a 3.0L diesel engine may have been built with a HPFP that could fail prematurely. The suspect period began on October 14, 2021, when 3.0L Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on May 5, 2023, when 3.0L Diesel engine vehicle production ended. The suspect period was determined using field data and engineering change records. Similar vehicles not included in the recall population are not equipped with the 3.0L Diesel engine, or were produced before or after the suspect period or were included in FCA US Recall ID Z96 (NHTSA Recall ID 22V-767), or were produced before or after the suspect period. The total affected vehicles for this model is 7,675. Production Dates : OCT 14, 2021 – MAY 05, 2023
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 3 : 2022-2023 Ram 1500 Vehicle Type : Body Style : PICKUP TRUCK Power Train : NR
Descriptive Information : Some 2022-2023 MY Ram 1500 vehicles equipped with a 3.0L diesel engine may have been built with a HPFP that could fail prematurely. The suspect period began on October 5, 2021, when 3.0L Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on March 23, 2023, when 3.0L Diesel engine vehicle production ended. The suspect period was determined using field data and engineering change records. Similar vehicles not included in the recall population are not equipped with the 3.0L Diesel engine, were included in FCA US Recall ID Z96 (NHTSA Recall ID 22V-767), or were produced before the suspect period. The total affected vehicles for this model is 26,671. Production Dates : OCT 05, 2021 – MAR 23, 2023
VIN Range 1 : Begin : NR End : NR Not sequential The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-263 Page 3 Description of Defect :
Description of the Defect : A HPFP failure may introduce internally failed component debris into the fuel system potentially causing fuel starvation.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : Fuel starvation may result in an unexpected loss of motive power, which can cause a vehicle crash without prior warning.
Description of the Cause : NR Identification of Any Warning
that can Occur : Vehicle occupants may notice a Malfunction Indicator Lamp, service Electronic Throttle Control indicator, a fuel leak at the HPFP, or excessive noise from the HPFP. Involved Components : Component Name 1 : High Pressure Fuel Pump Component Description : High Pressure Fuel Pump Component Part Number : 68501449AA Supplier Identification : Component Manufacturer
Name : Robert Bosch GmbH Address : Robert-Bosch-Platz 1
Gerlingen-Schillerhhe Foreign States 70839
Country : Germany Chronology :
• On February 9, 2022, the FCA US Technical Safety and Regulatory Compliance (“TSRC”) organization opened an investigation into 2021-2023 MY Jeep Wrangler, 2021-2023 MY Jeep Gladiator, and 2022-2023 MY Ram 1500 vehicles for potential premature high pressure fuel pump failures in vehicles equipped with the 3.0L diesel engine which may result in a stall. • From February 2022, through March 2023, FCA US TSRC conducted an analysis of stall patterns and vehicle history, determined that the affected vehicles were equipped with the Bosch CP4.2 high pressure fuel pump, and determined that the high pressure fuel pump was the origin of the stalls. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-263
Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
• As of March 30, 2023, FCA US is aware of seven customer assistance records, 126 warranty claims, eight field reports, and three other service records potentially related to this issue for all markets with dates of receipt ranging from April 14, 2022 to March 9, 2023. • As of March 30, 2023, FCA US is not aware of any accidents or injuries potentially related to this issue for all markets. • On April 6, 2023, FCA US determined, through the Vehicle Regulations Committee, to conduct a voluntary safety recall of the affected vehicles.
Description of Remedy :
Description of Remedy Program : FCA US will conduct a voluntary safety recall on all affected vehicles to
replace the HPFP, and inspect and, if necessary, replace additional fuel system components.
FCA US has a longstanding policy and practice of reimbursing owners who have incurred the cost of repairing a problem that subsequently becomes the subject of a field action. To ensure consistency, FCA US, as part of the owner letter, will request that customers send the original receipt and/or other adequate proof of payment to the company for confirmation of the expense.
How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production :
The remedy component is a HPFP with improved durability. NR Recall Schedule :
Description of Recall Schedule : **06/01/2023: FCA US will notify dealers and begin notifying owners
with the Final Owner Letter on or about 08/24/2023.
**04/13/2023: FCA US will notify dealers and begin notifying owners on or about 06/02/2023.
Planned Dealer Notification Date : JUN 02, 2023 – JUN 02, 2023
Planned Owner Notification Date : JUN 02, 2023 – JUN 02, 2023
* NR – Not Reported

**************************************************************************************************************

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-263
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Chrysler (FCA US, LLC) JUN 01, 2023 NHTSA Recall No. : 23V-263 Manufacturer Recall No. : 01A Manufacturer Information :
Manufacturer Name : Chrysler (FCA US, LLC) Address : 800 Chrysler Drive
CIMS 482-00-91 Auburn Hills MI 48326-2757
Company phone : 1-800-853-1403
Population :
Number of potentially involved : 45,832 Estimated percentage with defect : 1 %
Vehicle Information : Vehicle 1 : 2021-2023 Jeep Wrangler Vehicle Type : Body Style : SUV Power Train : NR
Descriptive Information : Some 2021-2023 MY Jeep Wrangler vehicles equipped with a 3.0L diesel engine may have been built with a high pressure fuel pump (“HPFP”) that could fail prematurely.
The suspect period began on November 2, 2021, when 3.0L Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on January 13, 2023, when 3.0L Diesel engine vehicle production ended. The suspect period was determined using field data and engineering change records. Similar vehicles not included in the recall population are not equipped with the 3.0L Diesel engine, were included in FCA US LLC (“FCA US”) Recall ID Z96 (NHTSA Recall ID 22V-767), or were produced before the suspect period. The total affected vehicles for this model is 11,486.
Production Dates : NOV 02, 2021 – JAN 13, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-263 Page 2 Vehicle 2 : 2021-2023 Jeep Gladiator Vehicle Type : Body Style : PICKUP TRUCK Power Train : NR
Descriptive Information : Some 2021-2023 MY Jeep Gladiator vehicles equipped with a 3.0L diesel engine may have been built with a HPFP that could fail prematurely. The suspect period began on October 14, 2021, when 3.0L Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on May 5, 2023, when 3.0L Diesel engine vehicle production ended. The suspect period was determined using field data and engineering change records. Similar vehicles not included in the recall population are not equipped with the 3.0L Diesel engine, or were produced before or after the suspect period or were included in FCA US Recall ID Z96 (NHTSA Recall ID 22V-767), or were produced before or after the suspect period. The total affected vehicles for this model is 7,675. Production Dates : OCT 14, 2021 – MAY 05, 2023
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 3 : 2022-2023 Ram 1500 Vehicle Type : Body Style : PICKUP TRUCK Power Train : NR
Descriptive Information : Some 2022-2023 MY Ram 1500 vehicles equipped with a 3.0L diesel engine may have been built with a HPFP that could fail prematurely. The suspect period began on October 5, 2021, when 3.0L Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on March 23, 2023, when 3.0L Diesel engine vehicle production ended. The suspect period was determined using field data and engineering change records. Similar vehicles not included in the recall population are not equipped with the 3.0L Diesel engine, were included in FCA US Recall ID Z96 (NHTSA Recall ID 22V-767), or were produced before the suspect period. The total affected vehicles for this model is 26,671. Production Dates : OCT 05, 2021 – MAR 23, 2023
VIN Range 1 : Begin : NR End : NR Not sequential The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-263 Page 3 Description of Defect :
Description of the Defect : A HPFP failure may introduce internally failed component debris into the fuel system potentially causing fuel starvation.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : Fuel starvation may result in an unexpected loss of motive power, which can cause a vehicle crash without prior warning.
Description of the Cause : NR Identification of Any Warning
that can Occur : Vehicle occupants may notice a Malfunction Indicator Lamp, service Electronic Throttle Control indicator, a fuel leak at the HPFP, or excessive noise from the HPFP. Involved Components : Component Name 1 : High Pressure Fuel Pump Component Description : High Pressure Fuel Pump Component Part Number : 68501449AA Supplier Identification : Component Manufacturer
Name : Robert Bosch GmbH Address : Robert-Bosch-Platz 1
Gerlingen-Schillerhhe Foreign States 70839
Country : Germany Chronology :
• On February 9, 2022, the FCA US Technical Safety and Regulatory Compliance (“TSRC”) organization opened an investigation into 2021-2023 MY Jeep Wrangler, 2021-2023 MY Jeep Gladiator, and 2022-2023 MY Ram 1500 vehicles for potential premature high pressure fuel pump failures in vehicles equipped with the 3.0L diesel engine which may result in a stall. • From February 2022, through March 2023, FCA US TSRC conducted an analysis of stall patterns and vehicle history, determined that the affected vehicles were equipped with the Bosch CP4.2 high pressure fuel pump, and determined that the high pressure fuel pump was the origin of the stalls. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-263
Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
• As of March 30, 2023, FCA US is aware of seven customer assistance records, 126 warranty claims, eight field reports, and three other service records potentially related to this issue for all markets with dates of receipt ranging from April 14, 2022 to March 9, 2023. • As of March 30, 2023, FCA US is not aware of any accidents or injuries potentially related to this issue for all markets. • On April 6, 2023, FCA US determined, through the Vehicle Regulations Committee, to conduct a voluntary safety recall of the affected vehicles.
Description of Remedy :
Description of Remedy Program : FCA US will conduct a voluntary safety recall on all affected vehicles to
replace the HPFP, and inspect and, if necessary, replace additional fuel system components.
FCA US has a longstanding policy and practice of reimbursing owners who have incurred the cost of repairing a problem that subsequently becomes the subject of a field action. To ensure consistency, FCA US, as part of the owner letter, will request that customers send the original receipt and/or other adequate proof of payment to the company for confirmation of the expense.
How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production :
The remedy component is a HPFP with improved durability. NR Recall Schedule :
Description of Recall Schedule : **06/01/2023: FCA US will notify dealers and begin notifying owners
with the Final Owner Letter on or about 08/24/2023.
**04/13/2023: FCA US will notify dealers and begin notifying owners on or about 06/02/2023.
Planned Dealer Notification Date : JUN 02, 2023 – JUN 02, 2023
Planned Owner Notification Date : JUN 02, 2023 – JUN 02, 2023
* NR – Not Reported

**************************************************************************************************************

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-263
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Chrysler (FCA US, LLC) APR 13, 2023 NHTSA Recall No. : 23V-263 Manufacturer Recall No. : 01A Manufacturer Information :
Manufacturer Name : Chrysler (FCA US, LLC) Address : 800 Chrysler Drive
CIMS 482-00-91 Auburn Hills MI 48326-2757
Company phone : 1-800-853-1403
Population :
Number of potentially involved : 45,711 Estimated percentage with defect : 1 %
Vehicle Information : Vehicle 1 : 2021-2023 Jeep Wrangler Vehicle Type : Body Style : SUV Power Train : NR
Descriptive Information : Some 2021-2023 MY Jeep Wrangler vehicles equipped with a 3.0L diesel engine may have been built with a high pressure fuel pump (“HPFP”) that could fail prematurely.
The suspect period began on November 2, 2021, when 3.0L Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on January 13, 2023, when production of the 3.0L Diesel engines ended. The suspect period was determined using field data and engineering change records. Similar vehicles not included in the recall population are not equipped with the 3.0L Diesel engine, or were produced before the suspect period. The total affected vehicles for this model is 11,486.
Production Dates : NOV 02, 2021 – JAN 13, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-263 Page 2 Vehicle 2 : 2021-2023 Jeep Gladiator Vehicle Type : Body Style : PICKUP TRUCK Power Train : NR
Descriptive Information : Some 2021-2023 MY Jeep Gladiator vehicles equipped with a 3.0L diesel engine may have been built with a HPFP that could fail prematurely. The suspect period began on October 14, 2021, when 3.0L Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on April 6, 2023, when FCA US LLC (“FCA US”) began containing suspect vehicles under plant control. The suspect period was determined using field data and engineering change records. Similar vehicles not included in the recall population are not equipped with the 3.0L Diesel engine, or were produced before or after the suspect period. The total affected vehicles for this model is 7,554. Production Dates : OCT 14, 2021 – APR 06, 2023
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 3 : 2022-2023 Ram 1500 Vehicle Type : Body Style : PICKUP TRUCK Power Train : NR
Descriptive Information : Some 2022-2023 MY Ram 1500 vehicles equipped with a 3.0L diesel engine may have been built with a HPFP that could fail prematurely. The suspect period began on October 5, 2021, when 3.0L Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on March 23, 2023, when production of the 3.0L Diesel engines ended. The suspect period was determined using field data and engineering change records. Similar vehicles not included in the recall population are not equipped with the 3.0L Diesel engine, or were produced before the suspect period. The total affected vehicles for this model is 26,671. Production Dates : OCT 05, 2021 – MAR 23, 2023
VIN Range 1 : Begin : NR End : NR Not sequential The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-263 Page 3 Description of Defect :
Description of the Defect : A HPFP failure may introduce internally failed component debris into the fuel system potentially causing fuel starvation.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : Fuel starvation may result in an unexpected loss of motive power, which can cause a vehicle crash without prior warning.
Description of the Cause : NR Identification of Any Warning
that can Occur : Vehicle occupants may notice a Malfunction Indicator Lamp, service Electronic Throttle Control indicator, a fuel leak at the HPFP, or excessive noise from the HPFP. Involved Components : Component Name 1 : High Pressure Fuel Pump Component Description : High Pressure Fuel Pump Component Part Number : 68501449AA Supplier Identification : Component Manufacturer
Name : Robert Bosch GmbH Address : Robert-Bosch-Platz 1
Gerlingen-Schillerhhe Foreign States 70839
Country : Germany Chronology :
• On February 9, 2022, the FCA US Technical Safety and Regulatory Compliance (“TSRC”) organization opened an investigation into 2021-2023 MY Jeep Wrangler, 2021-2023 MY Jeep Gladiator, and 2022-2023 MY Ram 1500 vehicles for potential premature high pressure fuel pump failures in vehicles equipped with the 3.0L diesel engine which may result in a stall. • From February 2022, through March 2023, FCA US TSRC conducted an analysis of stall patterns and vehicle history, determined that the affected vehicles were equipped with the Bosch CP4.2 high pressure fuel pump, and determined that the high pressure fuel pump was the origin of the stalls. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-263
Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
• As of March 30, 2023, FCA US is aware of seven customer assistance records, 126 warranty claims, eight field reports, and three other service records potentially related to this issue for all markets with dates of receipt ranging from April 14, 2022 to March 9, 2023. • As of March 30, 2023, FCA US is not aware of any accidents or injuries potentially related to this issue for all markets. • On April 6, 2023, FCA US determined, through the Vehicle Regulations Committee, to conduct a voluntary safety recall of the affected vehicles.
Description of Remedy :
Description of Remedy Program : FCA US will conduct a voluntary safety recall on all affected vehicles to
replace the HPFP, and inspect and, if necessary, replace additional fuel system components.
FCA US has a longstanding policy and practice of reimbursing owners who have incurred the cost of repairing a problem that subsequently becomes the subject of a field action. To ensure consistency, FCA US, as part of the owner letter, will request that customers send the original receipt and/or other adequate proof of payment to the company for confirmation of the expense.
How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production :
The remedy component is a HPFP with improved durability. NR Recall Schedule :
Description of Recall Schedule : **04/13/2023: FCA US will notify dealers and begin notifying owners on
or about 06/02/2023.
Planned Dealer Notification Date : JUN 02, 2023 – JUN 02, 2023
Planned Owner Notification Date : JUN 02, 2023 – JUN 02, 2023
* NR – Not Reported

SEOCONTENT-END