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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 Quantity Solenoid, Connector & Bolts
GC0145378Courtesy of CHRYSLER GROUP, LLC
  1. If necessary, Install the fuel quantity solenoid (2). Tighten screws (3) to 7 N.m (62 in. lbs.).
    Fig 2: Exploded View Of Fuel Injection Pump
    GC0145422Courtesy of CHRYSLER GROUP, LLC
  2. If necessary, using new sealing washers (2) and install the banjo bolts (1) the fuel supply (3) and return (4) fittings onto pump (5). Tighten 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 nuts (6) to 25 N.m (18 ft. lbs.).
  4. Install the blocker plate (7). Tighten nuts (8) to 25 N.m (18 ft. lbs.).
    Fig 3: High-Pressure Fuel Line
    GC0145382Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Fuel quantity solenoid removed for clarity.

  5. Install the new high-pressure fuel tube (1) to rear of pump and fuel rail.
  6. Tighten the high pressure fuel feed tube at the high pressure pump (1) to 28 N.m (20 ft. lbs.).
  7. Tighten the high pressure fuel feed tube at the fuel rail to 5 N.m (44 in. lbs) plus an additional 75 degrees.
  8. Install fuel tube clamp bolt. Tighten to 15 N.m (133 in. lbs.).
    Fig 4: Four Bolts
    GC0148216Courtesy of CHRYSLER GROUP, LLC
  9. Install the left engine mount and bracket. Tighten bolts (1) to 100 N.m (74 ft. lbs.).
  10. Connect the fuel quantity solenoid harness connector.
  11. Attach the fuel line routing clip at the left engine mount bracket.
    Fig 5: Low Pressure Supply Line & Return Line
    GC0145402Courtesy of CHRYSLER GROUP, LLC
  12. Connect the low pressure supply (1) and return (2) lines at high pressure pump.
    Fig 6: Accessory Pulley & Engine Lifting Bracket
    GC0085629Courtesy of CHRYSLER GROUP, LLC
  13. Lower the engine.
  14. Remove the (special tool #8534B, Fixture, Driveline Support).
  15. Install the right side and left side lower engine mount nuts. Tighten nuts to 54 N.m (40 ft. lbs.).
  16. Remove the front engine lift bracket (2).
  17. Remove the accessory drive idler pulley bracket (1).
    Fig 7: Fuel Injection Pump Timing Marks
    GC0082288Courtesy of CHRYSLER GROUP, LLC
  18. Position sprocket (1) onto pump shaft and install nut (4) finger tight.
    Fig 8: Locking Tool & Injection Pump Sprocket Mounting Nut
    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 timing belt. Refer to REMOVAL .
  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. .
  29. Install the water inlet elbow. Refer to TUBE, WATER INLET, INSTALLATION .
  30. Install the thermostat housing. Refer to THERMOSTAT, INSTALLATION .
    Fig 9: Oil Cooler Return Hose
    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 vehicle.
  35. Fill the cooling system. Refer to STANDARD PROCEDURE .
  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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