Pump, Fuel Injection: Installation: Installation

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 fuel lines deliver diesel fuel under extreme pressure from the injection pump to the fuel rail and from the fuel rail to the fuel injectors. This pressure may be as high as 1600 bar (23, 203 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 the high pressure circuits of the fuel system.

CAUTION:

Cranking the engine for an extended time without a fuel supply may damage the fuel injection pressure pump.

NOTE:

The fuel injection pressure pump must not be disassembled or opened. The only serviceable items are the sprocket and the fuel quantity solenoid.

Fig 1: Fuel Quantity Solenoid

Courtesy of CHRYSLER LLC

If removed, clean sealing surfaces and Install new O-ring seals onto the fuel quantity solenoid (1).
If removed, install the fuel quantity solenoid (1) and securely tighten fasteners (2).

Fig 2: Identifying Pump Shaft
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Position the fuel injection pump to the back of the support with the pump shaft inserted through the drive sprocket and the pump housing engaged over the mounting studs on the support.
Install the (Pump Rotation) (special tool #20150, Remover/Installer, High Pressure Fuel Pump) Tool (1) onto the threaded end of the pump shaft enough to align the pin in the pump shaft with the keyway in the hub of the drive sprocket and tighten finger tight.

Fig 3: Identifying Nuts & Fuel Injection Pump
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Install the three nuts (1) securing the fuel injection pump (2) and tighten to 25 N.m (18 ft. lbs.).

Fig 4: Identifying Pump Shaft
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Remove the (Pump Rotation) (special tool #20150, Remover/Installer, High Pressure Fuel Pump) Tool (1) from the threaded end of the pump shaft.

Fig 5: Identifying Sprocket
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Install the nut (1) securing the sprocket to the fuel injection pump and tighten to 50 N.m (37 ft. lbs.).
Remove the (special tool #20150, Remover/Installer, High Pressure Fuel Pump) (2).

Fig 6: Coolant Manifold
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Install the coolant manifold (1) at intake manifold.

Fig 7: Fuel Return Manifold
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Install the fuel return manifold (1) and securely tighten bolts (2).
Connect the fuel return hose (3) to the fuel injection pump and tighten clamp.
Connect the fuel injector return line to the fuel return manifold.

Fig 8: Fuel Injection Pump Guard
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Install the fuel injection pump guard (2) and securely tighten bolts (1).
Attach the fuel supply line to the retainer clip.

Fig 9: Identifying Quick Connect Fittings
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Connect the fuel supply (2) line quick-connect fitting.

Fig 10: Fuel Filter Protective Shield
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Install the fuel filter protective shield (1). Tighten bolts (2) to 6 N.m (53 in. lbs.).

Fig 11: Remove The Fuel Tube Between The Fuel Injection Pump And The Fuel Rail
Courtesy of CHRYSLER LLC

NOTE:
High pressure fuel tubes from the fuel injection pressure pump to the fuel rail or from the fuel rail to the fuel injector must be replaced with new units if removed.
Install new fuel tube (2) between the fuel injection pump (3) and the fuel rail (1). Tighten the union nuts to:
- Step 1 Tighten the union nut (1) at fuel rail to 20 N.m (177 in. lbs.).
- Step 2 Using a wrench to counter hold fitting, tighten union nut (3) at the fuel injection pump to 24 N.m (18 ft. lbs.).
Fig 12: Power Steering Pressure Line
Courtesy of CHRYSLER LLC
Install the upper timing cover. Refer to COVER(S), ENGINE TIMING, INSTALLATION or COVER(S), ENGINE TIMING, INSTALLATION .
Position the engine wire harness and attach the wire harness retainer to the upper timing cover.
Install the power steering pressure line (2) with support brackets and securely tighten bolts (1, 4).

Fig 13: Upper Clean Air To Turbocharger Tube
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Install the upper clean air to turbocharger tube (2). Refer to BODY, AIR CLEANER, INSTALLATION or BODY, AIR CLEANER, INSTALLATION .

Fig 14: Disconnect Fuel Quantity Solenoid Wire Harness Connector
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Connect the fuel quantity solenoid wire harness connector (2).

Fig 15: Fuel Quantity Solenoid Wire Harness Connector
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Connect the boost pressure wire harness connector.

Fig 16: 09 JC Rh Lower Splash Shield
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Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
Install the lower front closeout panel. Refer to FASCIA, FRONT LOWER, CLOSEOUT, INSTALLATION .
Position the right lower splash shield (2) and install retainers (1).
Install the right front wheel and tire. Refer to INSTALLATION .

Fig 17: Engine Belly Pan
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Install the belly pan.
Lower the vehicle.

Fig 18: Engine Cover
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Fill the cooling system. Refer to STANDARD PROCEDURE .
Connect the negative battery cable.
Start the engine and inspect the fuel connections for leaks.
Install the engine cover (1).