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Pump, Fuel Injection: Installation

CAUTION:

Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only.

NOTE:

Be sure pump is fully seated before tightening mounting nuts.

NOTE:

The fuel injection pump needs to be timed before it can be installed.

GC0161750Courtesy of CHRYSLER GROUP, LLC
  1. Position sprocket (2) to pump shaft.
  2. Align the notch on the pump sprocket (2) to the mounting hole in the pump flange.
    GC0162039Courtesy of CHRYSLER GROUP, LLC
  3. Install the fuel injection pump (2) vertically on the support and then rotate the pump up to 15 degrees in either direction until the bolt holes are aligned.
    GC0162120Courtesy of CHRYSLER GROUP, LLC
  4. Install the fuel injection pump bolts (2) and tighten to 25 N.m (18 ft. lbs.).
    GC0161849Courtesy of CHRYSLER GROUP, LLC
  5. Install the fuel injection pump (2) inner bolt (1) and tighten to 25 N.m (18 ft. lbs.).
    GC0161777Courtesy of CHRYSLER GROUP, LLC
  6. Connect the fuel return line (2) to the fuel injection pump.
  7. Install the fuel supply line (1) to the fuel injection pump and securely tighten the clamp.
    GC0162144Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The fuel tubes are a one time only use and must be replaced anytime they have been removed.

  8. Install the NEW  fuel tube to fuel injection pump and tighten union nut (2) finger tight.
  9. Install the bolt securing the fuel tube to intake manifold and tighten to 25 N.m (18 ft. lbs.).
  10. Tighten the fuel tube union nut (2) to 25 N.m (18 ft. lbs.).
    GC0162005Courtesy of CHRYSLER GROUP, LLC
  11. Connect engine oil pressure sensor harness connector (1).
    GC0161965Courtesy of CHRYSLER GROUP, LLC
  12. Connect the fuel quantity solenoid wire harness connector (1).
    GC0161971Courtesy of CHRYSLER GROUP, LLC
  13. Install the brake booster vacuum tube (2). Tighten bolts (1) to 25 N.m (18 ft. lbs.).
    GC0161963Courtesy of CHRYSLER GROUP, LLC
  14. Using a NEW  sealing washers, install the banjo bolt (1) onto the brake booster vacuum tube and tighten to 35 N.m (26 ft. lbs.).
    GC0162172Courtesy of CHRYSLER GROUP, LLC
  15. Install the coolant tube (2). Tighten nuts (1) to 25 N.m (18 ft. lbs.).
  16. Remove the support and lower the vehicle.
    GC0161773Courtesy of CHRYSLER GROUP, LLC
  17. Tighten the fuel tube union nut (1) at the fuel rail to 19 N.m (168 in. lbs.).
    GC0161959Courtesy of CHRYSLER GROUP, LLC
  18. Remove the (special tool #99360614, Pins, Camshaft Locking) (1).
    GC0161822Courtesy of CHRYSLER GROUP, LLC
  19. Install the plugs (1) from the cylinder head cover and tighten to 25 N.m (18 ft. lbs.).
  20. Install the engine cover.
  21. Connect the negative battery cable.
  22. Start engine and check for fuel leaks.
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