the next steps.
9. Turn the ignition to run, and allow the in-tank fuel pump to run a complete cycle (approx. 15
seconds). Capture all of the fuel expelled from the filter housing.
10. Using wiTECH, navigate to the PCM “Actuators” tab, and perform the Lift Pump Relay routine
to activate the in-tank fuel pump. This routine will run the pump for 20 seconds. Capture all fuel
expelled from the fuel filter housing.
11. Repeat Step 10, two additional times.
12. Install a new chassis mounted fuel filter element.
13. Place an appropriate catch basin under the engine mounted fuel filter housing to capture all
fuel expelled during the next steps.
14. Open the drain valve, and drain the engine mounted fuel filter housing.
15. Remove the filter element. Leave the drain valve open at this time.
16. Thoroughly clean the filter housing bowl of all debris.
17. Using wiTECH, perform the Lift Pump Relay routine to activate the in-tank fuel pump. The fuel
filter housing will begin to fill. If necessary, stop the routine before the housing begins to
overflow.

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18.
19.
20.
21.
22.
23.
24.
25.

26.
27.

28.

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Allow the housing to fully drain, and clean out any additional debris that is present.
Repeat Step 16, Step 17 and Step 18, two additional times.
Install a new fuel filter element, and tighten the cap to specifications.
Close the fuel filter housing drain valve.
Disconnect the fuel supply hose from the high pressure fuel injection pump.
Connect a suitable hose to the fuel supply hose, and route it into a suitable container.
Using wiTECH, perform the Lift Pump Relay routine to activate the in-tank fuel pump for 1
complete cycle to flush any contaminates out of the supply line.
Replace the High Pressure Fuel Injection Pump. The pump has been updated and requires
additional steps to install. Please refer to the High Pressure Fuel Injection Pump Installation
procedure in Step 1 below.
Replace the High Pressure Fuel Rail. Refer to Service Library, Service Information Section
14-Fuel System > Fuel Delivery, Diesel > Rail, Fuel > Removal and Installation.
Replace all 6 fuel injectors, and injector connector tubes. Refer to Service Library, Service
Information Section 09 – Engine, 6.7L Diesel > Fuel Injection > Injector(s), Fuel > Removal,
and Installation.
Install new high pressure fuel rail to injector connector tube fuel lines.

NOTE: Ensure that the provided fuel line isolators (PN 68447788AA) are properly secured
onto the #3 and #4 fuel rail to injector connector tube fuel lines as shown (Fig. 2) .

Fig. 2
Fuel Lines With Isolators

29. Install new high pressure fuel injection pump to rail supply lines.
30. Attach a suitable hose to the fuel return line fitting left disconnected at the tank in Step 5.
31. Route the hose into a suitable container.

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CAUTION! The PCM MUST be programmed with the correct calibration to support the new
High Pressure Fuel Injection pump. If the correct PCM calibration with the CP3.3
injection pump description is not showing in wiTECH, “STOP” and contact Star.
NOTE: Install a battery charger to ensure battery voltage does not drop below 13.2 volts. Do
not allow the charging voltage to climb above 13.5 volts during the flash process.
NOTE: If this flash process is interrupted/aborted, the flash should be restarted.
32. Reprogram the PCM with the correct calibration for the new High Pressure Fuel Injection
Pump. Ensure that the calibration being selected is labeled with CP3.3 in the calibration
description.
33. Clear all DTCs that may have been set in any module due to reprogramming. The wiTECH
application will automatically present all DTCs after the flash and allow them to be cleared.
34. Using wiTECH, perform the 9Oil Life Restore9 procedure located in the ECM 9Misc Functions”.
35. Prime the fuel system. Refer to Service Library, Service Information Section 14 – Fuel
System > Fuel Delivery, Diesel > Standard Procedure > Fuel System Priming, Diesel.
36. Start the engine, and allow it to run until approximately 2-3 gallons of fuel has been captured
from the fuel return line. This ensures that any debris in any of the remaining fuel return
system components, including the cylinder head, has been fully expelled from the system.
37. Reconnect the chassis fuel return line at the tank.
38. Install the fuel tank. Refer to Service Library Service Information Section 14-Fuel System >
Fuel Delivery, Diesel > Tank, Fuel > Installation.
39. Top off the fuel tank with fresh fuel if necessary, and verify the repair.
HIGH PRESSURE FUEL INJECTION PUMP INSTALLATION:
1. Remove the High Pressure Fuel Injection Pump. Refer to Service Library, Service Information
Section 14-Fuel System > Fuel Delivery, Diesel > Pump, Fuel Injection > Removal.
2. Remove the ECM and existing ECM support bracket. Refer to Service Library, Service
Information Section 08-Electrical > Electronic Control Modules >Module, Powertrain Control,
(PCM) 6.7L Diesel > Removal. Discard the original support bracket.
3. Remove all three fuel pump mounting studs in the front gear housing and discard them
(Fig. 3) .

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Fig. 3
Remove Stud Location
1
2
3
4
5

-

Fuel Pump Gear
Pump Mounting Studs
Pilot Adapter
Fuel Pump
Fuel Pump Mounting Nuts

4. Use a M8 x 1.25 tap to clean out all three holes where the studs were removed.
5. Install the fuel pump adapter plate **(Mopar PN 68573989AA /Supplier PN 5684301)** with the
flattened side pointing down so there is clearance for the cam positioning sensor and
counterbores facing the fuel pump.
6. Loosely install both of the 25mm, M8 bolts **(Mopar PN 68578596AA /Supplier PN 3420835)**
into the 2 bolt holes near the engine (Fig. 4) .

Fig. 4
Fuel Pump Mounting Adapter Plate
1 - New Fuel Pump Faster location
2 - Adapter Plate Faster

7. Loosely install bolt **(Mopar PN 4429446 /Supplier PN 3901446)** in location (1) (Fig. 4) to
help properly align the adapter before tightening bolts **(Mopar PN 68578596AA /Supplier PN
3420835). Tighten both bolts to 24 N·m (17.7 ft.lbs.).
8. Remove the loosely installed bolt in location (1) (Fig. 4) . This will be used in a later step.

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9. Before assembling the fuel pump, check and clean all mounting surface for nick, cuts or
damage. Also check pump shaft and gear. Clean all surfaces of dirt and grease.
NOTE: Do not use a hammer or press to install the pilot adapter on to the pump. The pilot
adapter can be install by hand.
10. Lubricate new O-ring **(Mopar PN 68444371AA /Supplier PN 5362113)** on the pump body
with engine oil and then install the pilot adapter onto the pump body with the smaller diameter
side towards the fuel pump (Fig. 5) .

Fig. 5
Pilot Adapter on Fuel Pump
1 - Pilot Adapter
2 - Pilot Adapter O-ring

11. Install the fuel pump gear onto the fuel pump shaft.
12. Using a new fuel pump washer **(Mopar PN 68086175AA /Supplier PN 5256193).** Install
washer and original nut to pump shaft and tighten the nut finger tight only.
13. Use the Fuel Pump Gear Holder to hold the fuel pump gear in place while tightening the fuel
pump gear mount nut to 105 N·m (77.4 ft.lbs.).

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-10-

14. Install the supply and return quick disconnect fittings onto the pump as shown below and
tighten to 24 N·m (17.7 ft lbs) (Fig. 6) .

Fig. 6
Supply and Return Fitting Location
1 - Return Quick Connect Fitting
2 - Supply Quick Connect Fitting

15. Fuel Injection Pump Phasing: Perform the following phasing procedure anytime the injection
pump has been removed and reinstalled.
16. Make sure engine cylinder 1 is at Top Dead Center (TDC) position.
17. Locate the end of the fuel injection pump shaft. Two numbers **(067 and 0)** are stamped into
the end of the shaft.
18. Rotate the injection pump shaft until the number **6 (located in the center of number 067 and
0) is positioned at 9 o’clock (Fig. 7) .

Fig. 7
Fuel Pump Shaft
1 - 9 O-Clock Position
2 - Shaft With **067** Markings

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18-099-22

NOTE: **It may be easier to remove the bolt from the CCV Breather Adapter.** (Fig. 8) .

Fig. 8
CCV Breather Adapter Bolt
1 - Adapter Bolt**

19. Position the injection pump to mounting flange on gear housing while aligning injection pump
shaft through back of injection pump gear. Be sure the number 6 is still at the 9 o’clock
position.
20. Before installing the pump use a clean rag, wipe the back side of the camshaft gear to remove
residual oil. It is only necessary to wipe the portion of the camshaft gear which is accessible
through the fuel pump bore in the gear housing.
21. The pump will need to be rotated to fit correctly in the space claim.
22. Install the long 60 mm cap screw **(Mopar PN 4429446 /Supplier PN 3901446).**(Fig. 9) first
loosely (yellow bolt in picture below).
23. Then install the two shorter 40 mm cap screws **(Mopar PN 4638665 /Supplier PN
3900678).**(Fig. 9) (blue bolt in picture below).

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-12-

Fig. 9
Fuel Pump Faster Location
1 - 60 mm cap screw **(Mopar PN 4429446 /Supplier PN 3901446)**
2 - 40 mm cap screws **(Mopar PN 4638665 /Supplier PN 3900678)**

24. Ensure that the fuel pump is sitting flush to the adapter face.
25. Ensure that there is adequate clearance to the cam position sensor and the paint cap is
removed if needed.
26. Tighten the fuel pump cap screws to 24Nm (17.7 ft.lbs.).
27. **Remove and discard old harness retainer stud (Fig. 10) .

Fig. 10
Harness Retainer Stud Location
1 - Harness Retainer Stud.

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18-099-22

28. Install the fuel pump tail support bracket to fuel pump. Loosely install the tail support bracket
on the fuel pump using **30mm M8 bolt (Mopar PN 4429114 /Supplier PN 3902114)**(Fig. 11) .

Fig. 11
Fuel Pump Tail Support Bracket Location
1 - Tail Support Bracket Mounting Bolt
2 - Fuel Line Stand off Tail Support

29. Loosely install the fuel line standoff to block through the tail support **(Mopar PN 68573994AA
/Supplier PN 5685063).**
30. Tighten both ends of the fuel pump tail support to 24 N·m (17.7 ft.lbs.).
31. The tie down bracket Must be loosened so it can be rotated and positioned to be secured to
the leg of the fuel pump tail support to ensure there is no twisting of the main engine harness.
The tie down bracket can be loosened by inserting a small flat head screwdriver or pic, into
a slot in the tie down (Fig. 12) .

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-14-

Fig. 12
Main Harness Tie down Bracket
1 - Slot Location to Loosen Tie Down

32. With the tie down bracket still loose around the main engine harness, secure the tie down
bracket to the tail of the fuel pump tail support using bolt **(Mopar PN 4429630 /Supplier PN
3900630)** and tighten bolt to 10 N·m (7.3 ft.lbs.). Tighten the tie down bracket around the
main engine harness using the zip closure (Fig. 13) .

Fig. 13
Main Engine Harness Tie down Bracket
1 - Harness Bracket and Faster

33. Finger tighten both fuel tube union nuts at the pump and the fuel rail. Make sure the bracket
slot aligns to the standoff, slide bracket along the tube to align if slightly off.
34. Finger tighten on the M8 nut **(Mopar PN 4429689 /Supplier PN 3900589).**
35. Tighten the union nut at the pump first then the fuel rail to proper tighten 55 N·m (40.5 ft.lbs.)
(Fig. 14) .

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18-099-22

Fig. 14
Fuel Rail Faster
1 - Union Nut

36. Tighten the High-Pressure Pump to Fuel Rail Supply line bracket bolt **bracket M8, 115 mm
bolt (Mopar PN 68573994 /Supplier PN 5685063)** to proper tighten 20 N·m (14.7 ft.lbs.).
37. Ensure there is no interference with the breather hose, pull the breather hose away from the
High-Pressure line if there is contact.
NOTE: There will only be 1 High-Pressure Pump to Fuel Rail Supply line.
NOTE: The rail block nut is a one time use part. If this nut is ever loosened or removed, it
must be replaced with a new block of nut.
38. The second supply port in the rail will need to be blocked off using rail block off nut **(Mopar
PN 68573999AA /Supplier PN 5688160)** and tighten to 55 N·m (40.5 ft.lbs.).
39. Install the new ECM mounting bracket **(Mopar PN 68574000AA /Supplier PN 5684423)**
using the same top bolts that came out of the original mounting bracket install them in the
new mounting bracket and tighten to 24 N·m (17.7 ft.lbs.).

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-16-

40. Using the provided bottom bolts **(Mopar PN 68578595AA /Supplier PN 5689141)** install
them into the new mounting bracket and tighten to 24 N·m (17.7 ft.lbs.) (Fig. 15) .

Fig. 15
New ECM Mounting Bracket and Faster Location
1 - Original Bracket Bolts
2 - New Bolts (PN 5689141)

41. Replace the power steering pressure hose **(Mopar PN 68359768AF /Supplier PN 5708745)**
from pump to hydroboost with the line provide in the kit.
42. Install the ECM to the new mounting bracket with the same hardware from when it was
originally removed. Tighten all bolts to 24 Nm (17.7 ft. lbs)
43. Connect the engine and transmission wire harness connector to the PCM and rotate the
latches closed.
44. Install the fasteners securing the engine wire harness and the transmission wiring harness to
the ECM and tighten them to 10 N·m (7.3 ft.lbs.).
45. Connect the low-pressure return line **(Mopar PN 68573997AA /Supplier PN 5684067)** to the
fuel filter support bracket .
46. Connect the low-pressure supply line **(Mopar PN 68573996AA /Supplier PN 5687735)** to
the fuel filter housing.
47. Connect the low-pressure supply and return lines to the fuel pump.
48. Reattach the standoff clip between the drain line and the harness.

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49. Install and connect Engine Wiring Harness Jumper **(Mopar PN 68573991AA /Supplier PN
5683566)** to Fuel Quantity Solenoid. Connect the female side of the jumper harness to the
engine wiring harness that originally attached to the Fuel Quantity Solenoid (Fig. 16) .

Fig. 16
Location of Tie down on Quantity Solenoid
1 - Tie Down

50. Connect the male side of the jumper to the Fuel Quantity Solenoid on the fuel pump.
51. Tie down the jumper using the provided zip-tie **(Mopar PN 68038172AA / Supplier PN
3062329)** (1) as shown in the picture below.
52. Using the provided zip-ties **(Mopar PN 68038172AA / Supplier PN 3062329)** attach the
swivel bracket to the fuel line standoff and secure the wire harness pig tail to the swivel
bracket (Fig. 17) .

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-18-

Fig. 17
Tie Down LocationSwivel Bracket Tie Down Location
1 - Tie Down

53. Connect the negative battery cable(s).
54. Complete the fuel system repair. Go back to Step 26 of the Repair Procedure.

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18-099-22

POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
NOTE: The in-tank lift pump replacement is already part of the kit installation LOP.
NOTE: Dealers that are charged for a Fuel Disposal fee must enter the reimbursement
request as a sublet repair in the Special Service section of the claim. The request for
reimbursement must be supported with a copy of the Fuel Disposal Fee invoice
when the claim is submitted for review.
Labor Operation
No:
14-45-01-97

Description

Skill Category

Amount

Kit - Fuel System Install and Flush
Fuel System
(2 - Skilled)

10 - Diesel

10.3 Hrs.

Description

Skill Category

Amount

Dual Alternator Equipped
(2 - Skilled)

10 - Diesel

0.5 Hrs.

Adaptive Steering System Equipped 10 - Diesel
(Sales Code SJE)
(2 - Skilled)

0.6 Hrs.

OPTIONAL EQUIPMENT:
Labor Operation
No:
14-45-01-62
14-45-01-63

FAILURE CODE:
ZZ

Service Action