PUMP, Fuel Injection: Installation: 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.

Fig 1: FUEL INJECTION PUMP MOUNTING

Courtesy of CHRYSLER LLC

1 - FUEL INJECTION PUMP

2 - FUEL QUANTITY SOLENOID

1. Slip pump (1) over mounting studs.
2. Be sure pump is fully seated before tightening mounting nuts.  Tighten injection pump mounting nuts (2) to 24 N.m (18 ft. lbs.) torque.
   Fig 2: FUEL INJECTION PUMP SPROCKET

   Courtesy of CHRYSLER LLC
3. Position sprocket (1) to pump shaft and install nut (2) finger tight.
   Fig 3: HIGH PRESSURE FUEL LINE AT PUMP

   Courtesy of CHRYSLER LLC
4. Install banjo bolt for fuel line (4) at rear of injection pump. Tighten bolt to 28 N.m (20 ft. lbs.) torque.
5. Install fuel line (2) and fitting to rear of injection pump. Tighten fitting to 28 N.m (20 ft. lbs.) torque.
6. Connect electrical connector to high-pressure fuel sensor (1).
   Fig 4: FUEL INJECTION PUMP TIMING MARKS

   Courtesy of CHRYSLER LLC
7. Tighten injection pump sprocket nut (4) to 88 N.m (65 ft. lbs.) torque.
8. PUMP ALIGNMENT MARKS:  Rotate pump gear (1) until marks (2) and (3) are aligned.
9. Install timing belt.
10. Connect engine coolant hose near rear of injection pump.
11. Fill engine cooling system. Refer to COOLING .
12. Lower vehicle.
13. Connect negative battery cable.
14. Start engine and check for fuel leaks.