Pump-Fuel Injection: Installation

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

Align injection pump (1) with pump drive and slide into cylinder head.

Fig 1: INJECTION PUMP RETAINING BOLTS

Courtesy of DAIMLERCHRYSLER CORP.

1 - INJECTION PUMP

2 - INJECTION PUMP RETAINING BOLTS

3 - HIGH PRESSURE LINE TO FUEL RAIL

Install retaining bolts (2). See Figure. Torque to 14 N.m (124 lbs. in.).

Fig 2: INJECTION PUMP FUEL LINES

Courtesy of DAIMLERCHRYSLER CORP.

1 - RETURN LINE FROM FUEL RAIL

2 - INJECTION PUMP FEED LINE

3 - INJECTION PUMP

4 - HIGH PRESSURE LINE TO FUEL RAIL

Install fuel supply (2) and return lines (1) to injection pump. See Figure. Install bracket and retaining bolt. Torque bolt to 9 N.m (80 lbs. in.).

Connect high pressure fuel line (4) to fuel rail at injection pump. Torque line to 22 N.m (16 lbs. ft.).

Fig 3: Air Cleaner Housing Assembly

Courtesy of DAIMLERCHRYSLER CORP.

1 - TURBOCHARGER INLET HOSE

2 - MAF SENSOR RETAINING BOLT

3 - MAF SENSOR

4 - O-RING

5 - MAF SENSOR ELECTRICAL CONNECTOR

6 - AIR CLEANER ASSEMBLY

7 - INLET DUCT

8 - AIR CLEANER HOUSING ASSEMBLY BRACKET

Install air cleaner housing assembly (6). On 1.6L, (Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - INSTALLATION) or on 2.4L, (Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - INSTALLATION) .
Connect air cleaner inlet hose (7) and turbocharger inlet hose (1).
Connect MAF sensor (3) electrical connector.

Fig 4: Battery Location
Courtesy of DAIMLERCHRYSLER CORP.

1 - BATTERY

2 - PASSENGER SEAT
Connect negative battery (1) cable located under passenger seat.
WARNING: High-pressure fuel lines deliver fuel under extreme pressure from the injection pump to the injectors. This maybe as high as 1600 bar (23,200 psi). Use extreme caution when inspecting for high-pressure fuel leaks. Fuel under this amount of pressure can penetrate skin causing personal injury or death. Inspect high-pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system.
Start engine and check for leaks.
Install engine cover. On 1.6L, (Refer to ENGINE COVER - INSTALLATION) or on 2.4L, (Refer to ENGINE COVER - INSTALLATION) .