Fuel System

2008 Dodge Charger SE
2008 ENGINE Fuel System - 300, Charger & Magnum
FUEL DELIVERY
STANDARD PROCEDURE
FUEL SYSTEM PRESSURE RELEASE PROCEDURE
WARNING: The fuel system is under constant high pressure even with engine off.
Until the fuel pressure has been properly relieved from the system, do not
attempt to open the fuel system. Do not smoke or use open flames/sparks
when servicing the fuel system. Wear protective clothing and eye
protection. Make sure the area in which the vehicle is being serviced is in
a well ventilated area and free of flames/sparks.
A separate fuel pump relay is no longer used. A circuit within the Totally Integrated Power Module
(TIPM) is used to control the electric fuel pump located within the fuel pump module.
1. Remove fuel fill cap.

2. Disconnect fuel pump module electrical connector.
3. Start and run engine until it stalls.
4. Attempt restarting engine until it will no longer run.
5. Turn ignition key to the OFF position.
6. Place a rag or towel below fuel line quick-connect fitting at fuel rail.
7. Disconnect quick-connect fitting at fuel rail. See STANDARD PROCEDURE.
NOTE: After servicing the fuel system, one or more Diagnostic Trouble Codes (DTC's)
may have been stored in Powertrain Control Module (PCM) memory due to
disconnecting fuel pump module circuit. A diagnostic scan tool must be used to
erase a DTC.
TANK - DRAINING FUEL
1. Release fuel system pressure, see STANDARD PROCEDURE.

2. Remove the fuel pump module, see REMOVAL.
3. Drain fuel from fuel tank with approved siphoning equipment, store fuel in approved fuel storage
container.
SPECIFICATIONS
FUEL SYSTEM PRESSURE
400 kpa ±34 kpa (58 psi ± 5 psi)
SPECIFICATIONS - TORQUE
DESCRIPTION N.m Ft. Lbs. In. Lbs.
Monday, January 27, 2014 10:27:36

10:27:15 AM Page 1 © 2005 Mitchell Repair Information Company, LLC.
Accelerator Pedal 12 8.8 106

to Dash Nuts
Fuel Tank Strap 27 20
-
Bolts
Hose Clamps 3.5 - 31
Fuel Rail Mounting
11 - 100
Bolts-2.7L
Fuel Rail Mounting
28 - 250
Bolts-3.5L
Fuel Rail Mounting
11 - 100
Bolts-5.7L
Fuel Rail Mounting 11 - 100
Bolts-6.1L
SPECIAL TOOLS
FUEL
Monday, January 27, 2014 10:27:15 AM Page 2 © 2005 Mitchell Repair Information Company, LLC.
Fig. 1: Test Kit, Fuel

Courtesy of CHRYSLER LLC
Fig. 2: Adapters, Fuel Pressure Test-6539 and/or 6631

Fig. 3: Lock Ring Remover/Installer #9340

Fig. 4: Fuel Line Adapter 1/4

Fig. 5: O2S (Oxygen Sensor) Removal/Installer-C4907
Fig. 6: Oxygen sensor tool

FITTING-QUICK CONNECT
STANDARD PROCEDURE
FITTING-QUICK CONNECT
Different types of quick-connect fittings are used to attach the various fuel system components, lines and tubes.
These are: a single-button type, a two-button type, a pinch type, a single-tab type, a two-tab type or a plastic
retainer ring type. Some are equipped with safety latch clips. Some may require the use of a special tool for
disconnection and removal.
DISCONNECTING
WARNING: The fuel system is under a constant pressure (even with engine off).
Before servicing any fuel system hose, fitting or line, fuel system
pressure must be released. Refer to fuel system pressure release
procedure.
CAUTION: Before separating a quick-connect fitting, pay attention to what type of

fitting is being used by referring to Quick-Connect Fitting Removal. This
will prevent unnecessary fitting or fitting latch breakage.
CAUTION: The interior components (O-rings, clips) of quick-connect fittings are not
serviced separately, but new plastic spacers and latches are available for
some types. If service parts are not available, do not attempt to repair the
damaged fitting or fuel line (tube). If repair is necessary, replace the
complete fuel line (tube) assembly.
1. Perform fuel pressure release procedure. Refer to FUEL SYSTEM PRESSURE RELEASE
PROCEDURE .
2. Disconnect negative battery cable from battery.
3. Clean fitting of any foreign material before disassembly.
Fig. 7: Single Button Fitting

4. Single-Button Type Fitting: This type of fitting is equipped with a single push-button (2) located on the
quick-connect fitting.
Fig. 8: Fitting Latches

5. The push-button is attached to two internal latches (1). To disconnect, press on push-button with your
thumb and unlatch fitting from fuel line. Special tools are not required for disconnection. DO NOT
ATTEMPT TO PRY OR PULL UP ON PUSH-BUTTON. LATCHES WILL BE BROKEN.
Fig. 9: 2-Button Type Fitting

6. Perform fuel pressure release procedure. Refer to FUEL SYSTEM PRESSURE RELEASE
PROCEDURE .
7. Disconnect negative battery cable from battery.
8. Clean fitting of any foreign material before disassembly.
9. 2-Button Type Fitting: This type of fitting (1) is equipped with a push-button located on each side of
quick-connect fitting (2). Press on both buttons simultaneously for removal. Special tools are not required
for disconnection.
Fig. 10: Pinch Type Quick-Connect Fitting

10. Pinch-Type Fitting: This fitting (1) is equipped with two finger tabs (2). Pinch both tabs together while
removing fitting. Special tools are not required for disconnection.
Fig. 11: Single-Tab Type Fitting

11. Single-Tab Type Fitting: This type of fitting (3) is equipped with a single pull tab (1). The tab is
removable. After tab is removed, quick-connect fitting can be separated from fuel system component.
Special tools are not required for disconnection.
Fig. 12: Disconnecting Single-Tab Type Fitting

12. Press release tab on side of fitting to release pull tab (1). If release tab is not pressed prior to releasing
pull tab, pull tab will be damaged.
13. While pressing release tab on side of fitting, use screwdriver (2) to pry up pull tab.
14. Raise pull tab until it separates from quick-connect fitting.
Fig. 13: Typical Two-Tab Type Quick-Connect Fitting

15. Two-Tab Type Fitting: This type of fitting (2) is equipped with tabs located on both sides of fitting (1).
The tabs are supplied for disconnecting quick-connect fitting from component being serviced.
l To disconnect quick-connect fitting, squeeze plastic retainer tabs (1) against sides of quick-connect
fitting with your fingers. Tool use is not required for removal and may damage plastic retainer.
l Pull fitting from fuel system component being serviced.
l The plastic retainer will remain on component being serviced after fitting is disconnected. The O-
rings and spacer will remain in quick-connect fitting connector body.
Fig. 14: Plastic Retainer Ring Type Fitting

16. Plastic Retainer Ring Type Fitting: This type of fitting can be identified by the use of a full-round
plastic retainer ring (4) usually black in color.
l To release fuel system component from quick-connect fitting, firmly push fitting towards
component being serviced while firmly pushing plastic retainer ring into fitting (6). With plastic
ring depressed, pull fitting from component. The plastic retainer ring must be pressed squarely
into fitting body. If this retainer is cocked during removal, it may be difficult to disconnect
fitting. Use an open-end wrench on shoulder of plastic retainer ring to aid in disconnection.
l After disconnection, plastic retainer ring will remain with quick-connect fitting connector body.
l Inspect fitting connector body, plastic retainer ring and fuel system component for damage.
Replace as necessary.
Fig. 15: Latch Clip-Type 1

17. Latch Clips - Type 1: Depending on vehicle model and engine, 2 different types of safety latch clips are
used. Type-1 (4) is tethered to fuel line and type-2 is not. A special tool will be necessary to disconnect
fuel line after latch clip is removed. The latch clip may be used on certain fuel line/fuel rail connection, or
to join fuel lines together.
18. Pry up on latch clip with a screwdriver (3).
19. Slide latch clip toward fuel rail while lifting with screwdriver.
Fig. 16: Fuel Line Disconnection Using Special Tool

20. Insert special fuel line removal tool (Snap-On number FIH 9055-1 or equivalent) into fuel line (1). Use
tool to release locking fingers in end of line.
21. With special tool still inserted, pull fuel line from fuel rail.
22. After disconnection, locking fingers will remain within quick-connect fitting at end of fuel line.
23. Disconnect quick-connect fitting from fuel system component being serviced.
Fig. 17: Latch Clip-Type 2

24. Latch Clips - Type 2: Depending on vehicle model and engine, 2 different types of safety latch clips are
used. Type-1 is tethered to fuel line and type-2 is not. A special tool will be necessary to disconnect fuel
line after latch clip is removed. The latch clip may be used on certain fuel line/fuel rail connection, or to
join fuel lines together.
25. Type 2: Separate and unlatch small arms on end of clip and swing away from fuel line.
26. Slide latch clip toward fuel rail while lifting with screwdriver.
Fig. 18: Fuel Line Disconnection Using Special Tool

27. Insert special fuel line removal tool (Snap-On number FIH 9055-1 or equivalent) into fuel line (1). Use
tool to release locking fingers in end of line.
28. With special tool still inserted, pull fuel line from fuel rail.
29. After disconnection, locking fingers will remain within quick-connect fitting at end of fuel line.
30. Disconnect quick-connect fitting from fuel system component being serviced.
Fig. 19: EVAP Can. Vapor Hose

31. Wing Type: A special tool will not be necessary to disconnect this type of fitting (2). This line is used on
different fuel and emission components. The graphic shows the fitting used on an EVAP canister.
32. Use two fingers to push on fitting wings (2)
33. Pull and disconnect fitting while holding wings.
34. After disconnection, locking fingers will remain within quick-connect fitting.
CONNECTING
1. Inspect quick-connect fitting body and fuel system component for damage. Replace as necessary.
2. Prior to connecting quick-connect fitting to component being serviced, check condition of fitting and
component. Clean parts with a lint-free cloth. Lubricate with clean engine oil.
3. Insert quick-connect fitting into fuel tube or fuel system component until built-on stop on fuel tube or
component rests against back of fitting.
4. Continue pushing until a click is felt.

5. Single-tab type fitting: Push new tab down until it locks into place in quick-connect fitting.
6. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.).
7. Latch Clip Equipped: Install latch clip (snaps into position). If latch clip will not fit, this indicates fuel
line is not properly installed to fuel rail (or other fuel line). Recheck fuel line connection.
8. Connect negative cable to battery.
9. Start engine and check for leaks.
MODULE-FUEL PUMP
DESCRIPTION
MODULE - FUEL PUMP
Fig. 20: Fuel System

1 - Right Side Module

2 - Left Side Module
Fig. 21: Driver Side Module

1 - Electrical Connection
2 - Vapor Fittings
3 - Level Sensor
4 - Fuel Pump
Fig. 22: Passenger Side Module

1 - Vapor Fittings
2 - Siphon Hose
3 - Fuel Supply Line
4 - Pressure Regulator
Fig. 23: Passenger Side Module Top View

1 - Control Valve
2 - Fuel Supply Fitting
3 - Fuel Pressure Regulator
4 - Level Sensor
This vehicle uses a saddle type tank, a reservoir on both sides of the rear drive shaft. The fuel pump is in the
module on the left side of the vehicle and the fuel pressure regulator is in the module on the right side of
vehicle. The fuel outlet is on the right side and supplies fuel to the engine. The fitting on the fuel pump module
(left side) is a vapor line fitting that connects to the right side module. Both modules have fuel level sending
cards. There are 2 hoses that connect the modules together, one is the fuel supply line the other is a return or
siphon hose. The lines are removed from the fuel pump module when servicing either unit. The ORVR
(Onboard Refueling Vapor Recovery) control valve is in the right side module.
OPERATION
MODULE - FUEL PUMP
The way the pump works is as follows, fuel enters the reservoir of the driver side module. The fuel pump pumps
the fuel through the filter to the passenger side module through a supply line inside tank. The pressure regulator
inside the passenger side module regulates the pressure at 58 psi. All unused fuel that is not sent to the engine is
fed through a venturi at the bottom of the passenger side module. This creates a low pressure siphoning effect
and draws fuel from the passenger side of the tank and transfers it to the drivers side tank via siphon hose inside
the tank. While the vehicle is running the fuel in the passenger side of tank is continuously transferred to the
drivers side. Fuel will continue to fill the drivers side tank till it reaches the bridge section and then start to spill
over to the passenger side.
As stated above we have two fuel level senders, the reading of these senders are averaged out to give us the fuel
gauge reading. When we are diagnosing a sender concern the passenger side reading should never be higher
than the Drivers side reading. It is possible, depending on fuel level and driving habit before diagnosing, to spill
fuel over to the passenger side that might indeed show a lower resistance value than the driver side.
The fuel gauge gives an indication to the vehicle operator of the level of fuel in the fuel tank. This gauge is
controlled by the instrument cluster circuit board based upon cluster programming and a hard wired input
received by the cluster from the fuel level sending units on the modules in the fuel tank.
The instrument cluster continually monitors the fuel tank sending units to determine the level of fuel in the fuel
tank. The cluster then sends the proper fuel level messages to other electronic modules in the vehicle over the
Controller Area Network (CAN) data bus. For further diagnosis of the fuel gauge or the instrument cluster
circuitry that controls the gauge. Refer to DIAGNOSIS AND TESTING (Electrical Diagnostics) or
DIAGNOSIS AND TESTING (Service Information). The fuel gauge is serviced as a unit with the instrument
cluster.
The tech needs to order the correct part when replacing, the senders, modules, and tank as all are able to be
replaced individually.
REMOVAL
MODULE - FUEL PUMP
1. Release the fuel pressure, refer to FUEL SYSTEM PRESSURE RELEASE PROCEDURE .
2. Disconnect negative battery cable.
NOTE: The fuel level of the vehicle must be below 5/8 of a tank before you remove
the module lock-rings. If it is above that you can spill fuel in the vehicle.
Fig. 24: Draining Fuel

3. Drain partial fuel from fuel tank through the filler tube. Use a hard nylon tube, with a 30° cut on the end,
to push the check valve open to drain fuel from tank.
Fig. 25: Rear Seat

4. Remove the rear lower seat cushion.
Fig. 26: Pulling Rear Seat Up

5. Push seat back and up to remove seat cushion.
Fig. 27: Foam Pad Under Seat

6. Fold back the foam pad covering access cover for modules.
Fig. 28: Left Side Module Orientation

7. Disconnect the electrical connector from left side module.

8. Mark the module orientation.
Fig. 29: Removing/Installing Left Side Module Lock Ring Using Special Tool
9. Use special tool #9340 to remove left side module lock ring.
Fig. 30: Draining Left Side

10. Drain fuel from left side of fuel tank. Lift module up enough to push hose into tank and drain. Do not
spill fuel in interior of vehicle.
Fig. 31: Module Electrical Connectors

11. Disconnect the electrical connectors from the module top.

12. Remove the module top half.
Fig. 32: View Of Module Fuel Level Sending Card, Fuel Return Lines & Fuel Supply Line
13. The module fuel level sending card (1). The fuel return lines (2). The fuel supply line (3).
Fig. 33: Release Tab

14. Fuel line release tab, press in the tab and pull up on fuel line.
Fig. 34: Line Release

15. Remove fuel line.
Fig. 35: View Of Fuel Return Line, Saipan Return Line & Module
16. Remove fuel return line from lower module. Line unsnap from module.
Fig. 36: Hose Connections At Module

17. Return line removed.
Fig. 37: Hose Connections at Pump

18. Tip module on its side to drain remaining fuel from reservoir and remove module from vehicle.
INSTALLATION
MODULE - FUEL PUMP

1. Install pump module into tank.

2. Connect fuel return lines to module.
3. Lines connected.
4. Connect fuel supply line to module and make sure it is locked in place.
Fig. 41: Module Electrical Connectors

5. Connect electrical connectors to bottom of module top, Install module top to module bottom.

6. Install module and align marks on the module for proper orientation.
7. Install module lock-ring.

8. Use special tool #9340 to tighten left side module lock ring.
9. Connect the electrical connector to left side module.
Fig. 44: Locating Plastic Access Cover

10. Install plastic access cover.

11. Fold the foam pad covering access cover for modules back into place.

12. Install rear lower seat cushion
Fig. 47: Rear Seat

13. Rear lower seat cushion installed.

14. Fill fuel tank.

15. Connect negative battery cable.
16. Fill fuel tank. Use the scan tool to pressurize the fuel system. Check for leaks.
RAIL-FUEL
REMOVAL
RAIL - FUEL - 2.7L
WARNING: Release fuel system pressure before servicing fuel rail. Service vehicles
in well ventilated areas and avoid ignition sources. Never smoke while
servicing the vehicle.
1. Release fuel system pressure. Refer to FUEL SYSTEM PRESSURE RELEASE PROCEDURE .
2. Disconnect the negative battery cable.

3. Remove intake manifold plenum. Refer to REMOVAL (2.7L DOHC).
4. Cover intake manifold to prevent foreign material from entering engine.
5. Disconnect fuel supply tube quick connect fitting at the rear of the fuel rail, see STANDARD
PROCEDURE.
Fig. 49: Remove/Install Injector Connector

6. Disconnect electrical connectors at fuel injectors. Refer to Fig. 50. Push red colored slider away from
injector (1). While pushing slider, depress tab (2) and remove connector (3) from injector. The factory
fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification.
If harness is not tagged, note wiring location before removal.
Fig. 50: Injector Electrical Connectors

7. Remove mounting bolts on both sides of fuel rail.

8. Lift fuel rail straight up off of cylinder head.
9. Remove retaining clips from fuel injectors at fuel rail.
10. Remove fuel injector from fuel rail.
RAIL - FUEL - 3.5L
WARNING: Release fuel system pressure before servicing fuel rail. Service vehicles
in well ventilated areas and avoid ignition sources. Never smoke while
servicing the vehicle.
1. Release fuel system pressure. Refer to FUEL SYSTEM PRESSURE RELEASE PROCEDURE .
2. Disconnect the negative battery cable.
3. Remove intake manifold plenum. Refer to REMOVAL (3.5L).
4. Cover intake manifold to prevent foreign material from entering engine.
5. Disconnect fuel supply tube quick connect fitting at the rear of the fuel rail, see STANDARD
PROCEDURE.
Fig. 51: Remove/Install Injector Connector

6. Disconnect electrical connectors at fuel injectors. Refer to Fig. 52. Push red colored slider away from
injector (1). While pushing slider, depress tab (2) and remove connector (3) from injector. The factory
fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification.
If harness is not tagged, note wiring location before removal.

7. Remove mounting bolts on both sides of fuel rail.

8. Lift fuel rail straight up off of cylinder head.
9. Remove retaining clips from fuel injectors at fuel rail.
10. Remove fuel injector from fuel rail.
RAIL - FUEL - 5.7L
WARNING: The fuel system is under constant pressure even with engine off. Before
servicing fuel rail, fuel system pressure must be released.
Fig. 53: Removing/Installing Fuel Injectors Electrical Connectors

1. Disconnect electrical connectors at all 8 fuel injectors. Push red colored slider away from injector (1). See
Fig. 53. While pushing slider, depress tab (2) and remove connector (3) from injector. The factory fuel
injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If
harness is not tagged, note wiring location before removal.
2. Disconnect electrical connectors at all throttle body sensors.
Fig. 54: Locating Fuel Rail Mounting Bolts

3. Remove four fuel rail mounting bolts (1) and holddown clamps. See Fig. 54.
4. Gently rock and pull left side of fuel rail until fuel injectors just start to clear machined holes in intake
manifold. Gently rock and pull right side of rail until injectors just start to clear intake manifold head
holes. Repeat this procedure (left/right) until all injectors have cleared machined holes.
5. Remove fuel rail (with injectors attached) from engine.
6. If fuel injectors are to be removed, see REMOVAL.
RAIL - FUEL - 6.1L
WARNING: The fuel system is under constant pressure even with engine off. Before
servicing fuel rail, fuel system pressure must be released.
Fig. 55: Fuel Rail - 6.1L

CAUTION: The left (3) and right (1) fuel rails are replaced as an assembly. Do not
attempt to separate rail halves at connector tube (2). Due to design of tube,
it does not use any clamps. Never attempt to install a clamping device of
any kind to tube. When removing fuel rail assembly for any reason, be
careful not to bend or kink tube.
1. Remove fuel tank filler tube cap.

2. Perform Fuel System Pressure Release Procedure. See FUEL SYSTEM PRESSURE RELEASE
PROCEDURE.
3. Remove negative battery cable at battery.
4. Remove flex tube (air cleaner housing to engine).
Fig. 56: MAP Sensor Location - 6.1L

5. Remove electrical connector from MAP sensor (2) at rear of intake manifold (1).
6. Disconnect vacuum hose from fitting (3) at rear of intake manifold (1).
Fig. 57: Fuel Line At Fuel Rail - 6.1L

7. Disconnect fuel line (1) at fuel rail fitting. Refer to FITTING-QUICK CONNECT .
Fig. 58: Disconnecting Electrical Connectors

8. Disconnect electrical connectors at all 8 fuel injectors. First, pry up on red colored tab (2).
Fig. 59: Removing Connector From Fuel Injector

9. Then press on black colored tab (1) while removing connector (2) from fuel injector (3).

10. Remove four fuel rail mounting bolts (1).

11. Gently rock and pull left side of fuel rail until fuel injectors just start to clear machined holes in intake
manifold. Gently rock and pull right side of rail until injectors just start to clear intake manifold head
holes. Repeat this procedure (left/right) until all injectors have cleared machined holes.
12. Remove fuel rail (with injectors attached) from engine.
13. If fuel injectors are to be removed, refer to INJECTOR-FUEL .
INSTALLATION
RAIL - FUEL - 2.7L

1. Lightly lubricate the fuel injector O-rings with a couple drops of clean engine oil.
2. Install retaining clips on fuel injectors.
3. Push injectors into fuel injector rail until clips are in the correct position.
4. Position fuel rail over cylinder heads, and push rail into place. Tighten fuel rail mounting bolts to 11 N.m
(100 in. lbs.) torque.
5. Connect the fuel supply tube quick connect fitting to the fuel rail, see STANDARD PROCEDURE.
6. Connect the electrical connectors to the fuel injectors.
7. Install intake manifold plenum. Refer to INSTALLATION .
9. Use the scan tool to pressurize the fuel system. Check for leaks.
RAIL - FUEL - 3.5L

1. Lightly lubricate the fuel injector O-rings with a couple drops of clean engine oil.
2. Install retaining clips on fuel injectors.
3. Push injectors into fuel injector rail until clips are in the correct position.
4. Position fuel rail over cylinder heads, and push rail into place. Tighten fuel rail mounting bolts to 28 N.m
(250 in. lbs.) torque.
5. Connect the fuel supply tube quick connect fitting to the fuel rail, see STANDARD PROCEDURE.
6. Connect the electrical connectors to the fuel injectors.
7. Install intake manifold plenum. Refer to INSTALLATION .
9. Use the scan tool to pressurize the fuel system. Check for leaks.
RAIL - FUEL - 5.7L

1. If fuel injectors are to be installed, see INSTALLATION.

2. Clean out fuel injector machined bores in intake manifold.
3. Apply a small amount of engine oil to each fuel injector O-ring. This will help in fuel rail installation.
4. Position fuel rail/fuel injector assembly to machined injector openings in intake manifold.
5. Guide each injector into intake manifold. Be careful not to tear injector O-rings.
6. Push right side of fuel rail down until fuel injectors have bottomed on shoulders. Push left fuel rail down
until injectors have bottomed on shoulders.
7. Install 4 fuel rail holddown clamps and 4 mounting bolts (1). Tighten fuel rail mounting bolts to 11 N.m
(100 in. lbs.)

8. Connect electrical connector to throttle body.
Fig. 64: Removing/Installing Fuel Injectors Electrical Connectors

9. Connect electrical connectors at all fuel injectors. Push connector onto injector (1) and then push and lock
red colored slider (2). Verify connector is locked to injector by lightly tugging on connector.
10. Connect fuel line latch clip and fuel line to fuel rail. See STANDARD PROCEDURE.
11. Install air resonator to throttle body (2 bolts).
12. Install flexible air duct to air box.
13. Connect battery cable to battery.
RAIL - FUEL - 6.1L
1. If fuel injectors are to be installed, refer to INJECTOR-FUEL .

2. Clean out fuel injector machined bores in intake manifold.
3. Apply a small amount of engine oil to each fuel injector o-ring. This will help in fuel rail installation.
4. Position fuel rail/fuel injector assembly to machined injector openings in intake manifold.
5. Guide each injector into intake manifold. Be careful not to tear injector o-rings.
6. Push right side of fuel rail down until fuel injectors have bottomed on shoulders. Push left fuel rail down
until injectors have bottomed on shoulders.

7. Install and tighten four fuel rail mounting bolts (1). Tighten fuel rail mounting bolts to 11 N.m (100 in.
lbs.)
8. Connect electrical connectors at all fuel injectors. Push electrical connector onto injector. After
connection has been made, lock connector by pushing red colored slider tab downward. Verify connector
is locked to injector by lightly tugging on connector.
Fig. 66: Fuel Line At Fuel Rail - 6.1L

9. Connect fuel line (1) to fuel rail. Refer to FITTING-QUICK CONNECT .
Fig. 67: MAP Sensor Location - 6.1L

10. Connect vacuum hose to fitting (3).

11. Connect electrical connector to MAP sensor (2).
12. Install air resonator to throttle body.
13. Connect battery cable to battery.
REGULATOR-FUEL PRESSURE
REMOVAL
REGULATOR - FUEL PRESSURE

Fig. 69: Rear Seat



Fig. 72: Access Cover Right Side Module

7. Remove plastic access covers from floor pan right side.
Fig. 73: Right Side Module Orientation

8. Disconnect the fuel supply line from module.

Fig. 74: Tool 9430 Right Side Module

10. Use special tool #9340 to remove right side module lock ring.
Fig. 75: Draining Fuel From Right Side Of Fuel Tank

11. Drain fuel from right side of fuel tank. Lift module up enough to push hose into tank and drain. Do not
Fig. 76: Remove/Install Right Side Module

12. Pull module up and out of fuel tank.
Fig. 77: Fuel Pressure Regulator Location

13. Fuel Pressure regulator location.
Fig. 78: Fuel Pressure Regulator

14. Note location of ground wire tab location.
Fig. 79: Remove/Install Ground Wires

15. Remove ground wire.
Fig. 80: Removing Retaining Clip

16. Use a screwdriver and pry up on retaining clip.
Fig. 81: Retaining Clip

17. Clip in the off position.
Fig. 82: Removing/Installing Regulator

18. Fuel pressure regulator removed.
Fig. 83: O-Ring

19. Remove o-ring from module.
INSTALLATION
REGULATOR - FUEL PRESSURE
Fig. 84: O-Ring

1. Install o-ring.
Fig. 85: Ground Ring

2. Install ground ring.
Fig. 86: Removing/Installing Regulator

3. Install Fuel Regulator and ground ring. Note location of ground ring.

4. Install ground wire.
Fig. 88: Retaining Clip

5. Install Fuel Pressure Regulator retaining clip.

6. Install module into tank.

7. Align marks on the module for proper orientation.


9. Use special tool #9340 to tighten right side module lock ring.
10. Connect the fuel supply line to module.

11. Install plastic access covers to floor pan right side.


Fig. 95: Rear Seat


15. Fill fuel tank.

SENDING UNIT AND SENSOR-FUEL LEVEL
REMOVAL
SENDING UNIT AND SENSOR-FUEL LEVEL - RIGHT SIDE

Fig. 98: Rear Seat






Fig. 104: Electrical Connectors

11. Lift module up and out of tank as far as possible.

12. Disconnect the electrical connector from the bottom of the left side module.
13. Pump module left side.

14. Lift module top half off and tip lower half on its side to drain remaining fuel from the reservoir.
Fig. 106: Release Tab

15. Push in on the release tab on the fuel line fitting to release the fuel line from the fuel pump fitting.
Fig. 107: Line Release

16. Remove the Fuel supply line from the top of the bottom half of the module.
17. Fuel return line (1) and Saipan return line (2). Just pull tube up to release from module.

18. Remove the fuel return and Siphon return hoses from the bottom module.






24. Pull module up and out of fuel tank.
Fig. 115: Level Card Locking Tabs

25. Unlatch the fuel level sending card from module.
Fig. 116: Card Removed Pass Side

26. Fuel level sending card released.

27. Remove the ground wire from the check valve and fuel pressure regulator.
Fig. 118: Level Card Wires Pass Side

28. Remove fuel level sending card from module.

29. Cut tie straps from hoses to remove wiring harness for fuel level card.
SENDING UNIT AND SENSOR-FUEL LEVEL - LEFT SIDE

Fig. 120: Rear Seat






Fig. 126: Locating Electrical Connectors

11. Disconnect the electrical connector for the left side fuel level card from bottom of the module top.
12. Disconnect the electrical connector for the right side fuel level sending card.
13. Lift module top half off and tip lower half on its side to drain remaining fuel from the reservoir.
Fig. 127: Wire Location Left Card

14. Remove wire from module.
Fig. 128: Releasing Tabs From Card

15. Use a screwdriver to separate the locking tabs on the level sending card.
Fig. 129: Removing/Installing Level Card

16. Lift level sending card straight up and out of module.
Fig. 130: View Of Level Sender Card (Driver Side)

17. Disconnect the electrical wiring from module.

18. Remove level sending card.
INSTALLATION
SENDING UNIT AND SENSOR-FUEL LEVEL - LEFT SIDE
Fig. 131: Removing/Installing Level Card

1. Install level sending card, make sure that the locking tabs are locked on the card.
Fig. 132: Wire Location Left Card

2. Route wires in the proper location.

3. Install module top to module bottom.
Fig. 134: Electrical Connector Left Side Card

4. Connect the electrical connectors for right side fuel level sending card, left side module card and fuel
pump.


8. Connect the electrical connector to left side module and install plastic access cover.


10. Install rear lower seat cushion.
Fig. 139: Rear Seat


12. Fill fuel tank.

SENDING UNIT AND SENSOR-FUEL LEVEL - RIGHT SIDE
Fig. 141: Level Card Locking Tabs

1. Install level sending card, make sure that the locking tabs are locked on the card.
Fig. 142: Level Card Wires Pass Side

2. Route wires in the proper location.

3. Tie strap the wires harness to the hoses.

4. Feed hoses and wiring harness into fuel tank and over the center hump in tank.




10. Install the fuel return hoses to module.

11. Install fuel supply line to module.
12. Make sure that wires are routed properly.
Fig. 149: Wire Tie Strap

13. Make sure that the level sending card wire is tie strapped to the fuel supply line at the module.

14. Install left side module top to module bottom.
Fig. 151: Locating Electrical Connectors

15. Connect the electrical connectors for right side fuel level sending card, left side module card. Make sure
that wires are routed properly.




Fig. 156: Rear Seat


23. Fill fuel tank.

TANK-FUEL
REMOVAL
TANK - FUEL

Fig. 159: Rear Seat











16. Install both module temporally, hand tighten the lock ring to hold modules in place.
17. Raise vehicle and support.
18. Remove left rear tire.
Fig. 169: Locating Inner Splash Shield

19. Remove the inner splash shield.
Fig. 170: Vent Line

20. Disconnect the filler tube vent line.
Fig. 171: Remove/Install Filler Tube Clamp

21. Remove clamp from filler tube.
Fig. 172: Remove/Install Filler Tube

22. Remove metal filler tube from rubber tube on fuel tank.
23. Remove the exhaust system.
24. Remove the drive shaft, refer to REMOVAL .
Fig. 173: Driver Side Splash Shield

25. Remove the left underbody splash shield.
Fig. 174: Passenger Side Splash Shield+C4990

26. Remove the right underbody splash shield.
Fig. 175: EVAP Line

27. Disconnect the EVAP line in the right rear wheel well.
Fig. 176: Vapor Connection on Tank

28. Disconnect vapor line.
Fig. 177: Fuel Line Disconnected

29. Disconnect the fuel supply line.
Fig. 178: Tank Straps

30. Support fuel tank with transmission jack.

31. Fuel tank strap bolt locations.
Fig. 179: Tank Strap Bolts

32. Remove bolt for fuel tank strap.

33. Remove bolt for fuel tank strap.
Fig. 181: Tank Vent Line Routing

34. Lower tank and pull filler tube vent line through bracket.
Fig. 182: Fuel Tank Assembly


2 - Control Valve
3 - Left Side Module (Fuel Pump Module)
35. Lower Fuel tank and remove from vehicle.
Fig. 183: Left Side Module

36. Left Side Module (Fuel Pump Module).
Fig. 184: Module Pass Side

37. Right Side Module.
Fig. 185: Control Valve

38. Control Valve and lines.
INSTALLATION
TANK - FUEL
Fig. 186: Fuel Tank Assembly


2 - Control Valve
3 - Left Side Module (Fuel Pump Module)
1. Support fuel tank with transmission jack.
Fig. 187: Tank Vent Line Routing

2. Raise tank and push filler tube vent line through bracket.
Fig. 188: Tank Straps

3. Fuel tank strap bolt locations.

4. Install bolt for fuel tank strap and tighten.

5. Install bolt for fuel tank strap and tighten.
Fig. 191: Vapor Connection on Tank

6. Connect vapor line.
Fig. 192: Fuel Line Disconnected

7. Connect the fuel supply line.
Fig. 193: EVAP Line

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

9. Install the drive shaft, refer to INSTALLATION .
10. Install the exhaust system.

11. Install metal filler tube to rubber tube on fuel tank.
Fig. 195: Remove/Install Filler Tube Clamp

12. Install clamp to filler tube and tighten
Fig. 196: Vent Line

13. Connect the filler tube vent line.

14. Install the inner splash shield.
Fig. 198: Driver Side Splash Shield

15. Install the left underbody splash shield.
Fig. 199: Passenger Side Splash Shield+C4990

16. Install the right underbody splash shield.

17. Install left rear tire.
18. Lower vehicle.








Fig. 207: Rear Seat


31. Fill fuel tank.

TUBE-FUEL TANK FILLER
REMOVAL
TUBE - FUEL TANK FILLER
Fig. 209: Filler Tube Assembly


2. Drain fuel from tank.
3. Fuel filler tube assembly.
Fig. 210: Filler Tube Door

4. Open filler tube door.
Fig. 211: Removing/Installing Retaining Wire

5. Remove retaining wire from inside filler tube rubber.
Fig. 212: Pushing Rubber Back

6. Start removing rubber from body sheet metal.
Fig. 213: Squeezing Rubber & Pushing In

7. Squeeze rubber and push in.
Fig. 214: Filler Tube Rubber At Body Opening

8. Filler tube and rubber removed from body sheet metal.

9. Raise vehicle and support.

10. Remove the left rear tire.
11. Remove the left inner splash shield.
Fig. 216: Disconnect/Connect Filler Tube Vent Line

12. Disconnect the filler tube vent line.
Fig. 217: Filler Tube Mounting Screw

13. Remove the filler tube mounting bolt.
Fig. 218: Splash Shield Driver Side

14. Remove the under body splash shield.
Fig. 219: Filler Tube

15. Loosen the filler tube hose clamp. Leave the clamp tight on the hose and fuel tank location.
Fig. 220: Removing Rubber at Tank

16. Move clamp toward the fuel tank.

17. Remove the filler tube assembly from the vehicle.
INSTALLATION
TUBE - FUEL TANK FILLER
Fig. 222: Filler Tube Assembly

1. Filler tube assembly.
Fig. 223: Filler Tube Rubber Profile

2. Groove in filler tube rubber is for the body sheet metal.

3. Insert filler tube into the fuel tank rubber hose.
Fig. 225: Removing Rubber at Tank

4. Slide hose clamp into place and tighten.
Fig. 226: Filler Tube

5. Hose clamp in place and tighten.
Fig. 227: Filler Tube Mounting Screw

6. Install filler tube mounting bolt.
Fig. 228: Disconnect/Connect Filler Tube Vent Line

7. Install Filler tube vent line.
Fig. 229: Splash Shield Driver Side

8. Install the underbody splash shield.

9. Install the left inner splash shield.

10. Install the left rear tire.
11. Lower vehicle.
Fig. 231: Filler Tube Rubber At Body Opening

12. Filler tube rubber at body opening.

13. Pull rubber through opening and install to body. Make sure that the sheet metal is in the groove in the
rubber.
Fig. 232: Retaining Wire Started

14. Start the metal wire retaining wire in the groove on the inside of the filler tube rubber.
Fig. 233: Removing/Installing Retaining Wire

15. Work wire retaining wire around the rubber.
Fig. 234: Filler Tube Door

16. Wire retainer install.

18. Fill fuel tank.

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2008 Dodge Charger SE

2008 ENGINE Fuel System - 300, Charger & Magnum

FUEL SYSTEM PRESSURE RELEASE PROCEDURE

1. Remove fuel fill cap.

TANK - DRAINING FUEL

1. Release fuel system pressure, see STANDARD PROCEDURE.

FUEL SYSTEM PRESSURE

400 kpa ±34 kpa (58 psi ± 5 psi)

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

Monday, January 27, 2014 10:27:36

Accelerator Pedal 12 8.8 106

Fig. 1: Test Kit, Fuel

Fig. 2: Adapters, Fuel Pressure Test-6539 and/or 6631

Fig. 3: Lock Ring Remover/Installer #9340

Fig. 4: Fuel Line Adapter 1/4

Fig. 5: O2S (Oxygen Sensor) Removal/Installer-C4907

Courtesy of CHRYSLER LLC

Fig. 6: Oxygen sensor tool

CAUTION: Before separating a quick-connect fitting, pay attention to what type of

Fig. 7: Single Button Fitting

Fig. 8: Fitting Latches

Fig. 9: 2-Button Type Fitting

Fig. 10: Pinch Type Quick-Connect Fitting

Fig. 11: Single-Tab Type Fitting

Fig. 12: Disconnecting Single-Tab Type Fitting

Fig. 13: Typical Two-Tab Type Quick-Connect Fitting

Fig. 14: Plastic Retainer Ring Type Fitting

Fig. 15: Latch Clip-Type 1

Fig. 16: Fuel Line Disconnection Using Special Tool

Fig. 17: Latch Clip-Type 2

Fig. 18: Fuel Line Disconnection Using Special Tool

Fig. 19: EVAP Can. Vapor Hose

4. Continue pushing until a click is felt.

MODULE - FUEL PUMP

Fig. 20: Fuel System

1 - Right Side Module

Fig. 21: Driver Side Module

Fig. 22: Passenger Side Module

Fig. 23: Passenger Side Module Top View

MODULE - FUEL PUMP

MODULE - FUEL PUMP

Fig. 24: Draining Fuel

Fig. 25: Rear Seat

4. Remove the rear lower seat cushion.

Fig. 26: Pulling Rear Seat Up

5. Push seat back and up to remove seat cushion.

Fig. 27: Foam Pad Under Seat

Fig. 28: Left Side Module Orientation

7. Disconnect the electrical connector from left side module.

Fig. 30: Draining Left Side

Fig. 31: Module Electrical Connectors

11. Disconnect the electrical connectors from the module top.

Fig. 33: Release Tab

Fig. 34: Line Release

15. Remove fuel line.

Fig. 36: Hose Connections At Module

17. Return line removed.

Fig. 37: Hose Connections at Pump

MODULE - FUEL PUMP

Fig. 38: Hose Connections At Module