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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.

GC0145378Courtesy of CHRYSLER GROUP, LLC
  1. If necessary, install the fuel quantity solenoid (2). Tighten the screws (3) to 7 N.m (62 in. lbs.).
    GC0145422Courtesy of CHRYSLER GROUP, LLC
  2. If removed, install the banjo bolts (1) using NEW  sealing washers (2) on the fuel injection pump (5) supply (3) and return (4) fittings. Tighten the banjo bolts to 28 N.m (21 ft. lbs.).
    NOTE:

    Be sure pump is fully seated before tightening mounting nuts.

  3. Install the fuel injection pump (5). Tighten the nuts (6) to 25 N.m (18 ft. lbs.).
  4. Install the blocker plate (7). Tighten the nuts (8) to 25 N.m (18 ft. lbs.).
    GC0145382Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Fuel quantity solenoid removed for clarity.

  5. Install a NEW  fuel tube (1) to the rear of the fuel injection pump and the fuel rail.
  6. Tighten the fuel tube at the fuel injection pump (1) to 28 N.m (20 ft. lbs.).
  7. Tighten the fuel tube at the fuel rail to 5 N.m (44 in. lbs) plus an additional 75 degrees.
  8. Install fuel tube clamp bolt and tighten to 15 N.m (133 in. lbs.).
    GC0148216Courtesy of CHRYSLER GROUP, LLC
  9. Install the left engine mount and bracket. Tighten the bolts (1) to 100 N.m (74 ft. lbs.).
  10. Connect the fuel quantity solenoid wire harness connector.
  11. Attach the fuel line routing clip at the left engine mount bracket.
    GC0145402Courtesy of CHRYSLER GROUP, LLC
  12. Connect the low pressure supply (2) and return (1) lines at high pressure pump.
  13. Lower the engine.
  14. Remove the (special tool #8534C, Fixture, Driveline Support).
  15. Install the right side and left side lower engine mount nuts. Tighten nuts to 54 N.m (40 ft. lbs.).
    GC0085629Courtesy of CHRYSLER GROUP, LLC
  16. Remove the front engine lift bracket (2).
  17. Remove the accessory drive idler pulley bracket (1).
    GC0082288Courtesy of CHRYSLER GROUP, LLC
  18. Position the sprocket (1) onto pump shaft and install nut (4) finger tight.
    GC0145381Courtesy of CHRYSLER GROUP, LLC
  19. Using (special tool #VM.1055, Locking Tool) (1), tighten injection pump sprocket nut (2) to 88 N.m (65 ft. lbs.).
  20. Install the timing belt. Refer to the appropriate service information.
  21. Install the generator. Refer to GENERATOR, INSTALLATION .
  22. Connect the EGR air flow control valve harness connector.
  23. Connect the Charge Air Cooler (CAC) outlet hose from the EGR air flow control valve.
  24. Install the serpentine belt. Refer to BELT, SERPENTINE, INSTALLATION .
  25. Install the cooling fan. Refer to FAN, COOLING, INSTALLATION .
  26. Connect the upper radiator hose at radiator.
  27. Connect the coolant reservoir hose at radiator.
  28. Install the air cleaner body. Refer to BODY, AIR CLEANER, INSTALLATION .
  29. Install the water inlet elbow. Refer to TUBE, WATER INLET, INSTALLATION .
  30. Install the thermostat housing. Refer to THERMOSTAT, INSTALLATION .
    GC0148215Courtesy of CHRYSLER GROUP, LLC
  31. Install the oil cooler return hose (1) at water pump inlet tube.
  32. Install the two oil cooler return tube bolts. Tighten bolts in to 15 N.m (133 in. lbs.).
  33. Install the front lower splash shield.
  34. Lower the vehicle.
  35. Fill the cooling system. Refer to LEVEL CHECK .
  36. Install the engine cover and securely tighten the four nuts.
  37. Connect the negative battery cable.
  38. Remove the steering wheel lock.
  39. Start engine and check for fuel leaks.
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