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Home >> Jeep >> 2021 >> Grand Cherokee Trackhawk >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Fuel System >> Fuel Delivery, Diesel >> Pump, Fuel Injection, High Pressure >> Installation
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Pump, Fuel Injection, High Pressure: Installation

WARNING:

High-pressure lines deliver diesel fuel under extreme pressure from the injection pump to the fuel injectors. This may be as high as 2000 bar (29, 008 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 fuel system.

CAUTION:

Do Not Force the high pressure pump into the right timing cover or attempt to seat it by drawing it in with the bolts. The pump gear must be properly aligned with the drive gear on the camshaft before the high pressure pump will seat on the cylinder head mounting surface. Failure to properly align drive gears will damage the high pressure pump or camshaft drive gear.

NOTE:

The fuel injection pump needs to be timed before it can be installed. Use a commercially available degree wheel to time the fuel injection pump.

GC0146830Courtesy of CHRYSLER GROUP, LLC
  1. If removed, install the fuel quantity solenoid (1). Refer to SOLENOID, FUEL QUANTITY, INSTALLATION .
    GC0146835Courtesy of CHRYSLER GROUP, LLC
  2. If removed, install the gear (2) and nut (1) onto the fuel injection pump (3). Tighten the nut (1) to 50 N.m (37 ft. lbs.).
    GC0146842Courtesy of CHRYSLER GROUP, LLC
  3. Mark the center line on the fuel quantity solenoid (1) with a paint pen as making a reference to zero 0°.
    GC0146847Courtesy of CHRYSLER GROUP, LLC
  4. Using a paint pen, mark the gear and hole (1) as a reference mark.
  5. Rotate the pump shaft so the paint mark on the gear and hole (1) aligns with the 0° reference mark (2) on pump.
    GC0146843Courtesy of CHRYSLER GROUP, LLC
  6. Align the commercially available degree wheel to zero (2) with the center line on fuel quantity solenoid (1).
    GC0146848Courtesy of CHRYSLER GROUP, LLC
  7. Rotate the pump gear counter clockwise  so the index mark (1) on drive gear aligns at the 65° mark on the degree wheel (2).
    GC0146837Courtesy of CHRYSLER GROUP, LLC
  8. Install a NEW  O-ring seal (1) onto the high pressure pump (2).
    GC0146836Courtesy of CHRYSLER GROUP, LLC
  9. Install the (special tool #VM.10345, Tool, High Pressure Pump Installation) (2) into the right upper timing cover (1).
  10. Position the high pressure pump onto the (special tool #VM.10345, Tool, High Pressure Pump Installation) and install the high pressure pump.
  11. Remove the (special tool #VM.10345, Tool, High Pressure Pump Installation) (2).
    GC0146833Courtesy of CHRYSLER GROUP, LLC
  12. Install the three fuel injection pump bolts (1) and tighten to 25 N.m (18 ft. lbs.).
    GC0146740Courtesy of CHRYSLER GROUP, LLC
    NOTE:

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

  13. Install the NEW  left high pressure fuel tube (11) and tighten union nuts (10, 12) finger tight:
    • Tighten the union nut (10) to 5 N.m (44 in. lbs.) plus an additional 75 degrees turn.
    • Tighten the union nut (12) to 11 N.m (8 ft. lbs.) plus an additional 75 degrees turn.
  14. Install the NEW  right high pressure fuel tube (3) and tighten union nuts (2, 4) finger tight:
    • Tighten the union nut (4) to 5 N.m (44 in. lbs.) plus an additional 75 degrees turn.
    • Tighten the union nut (2) to 11 N.m (8 ft. lbs.) plus an additional 75 degrees turn.
    GC0146844Courtesy of CHRYSLER GROUP, LLC
  15. Install the engine wire harness assembly (1) to the intake manifold and push down to seat the wire harness retainers. Tighten the bolts (2) to 11 N.m (8 ft. lbs.).
    GC0158181Courtesy of CHRYSLER GROUP, LLC
    NOTE:

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

  16. Remove the protective caps from the fuel injectors and fuel rail.
  17. Install the NEW  right side fuel tubes (2) onto fuel injector No. 1, 2 and tighten union nuts (1, 3) finger tight:
    • Tighten the union nut (1) to 5 N.m (44 in. lbs.) plus an additional 75 degrees turn.
    • Tighten the union nut (3) to 11 N.m (8 ft. lbs.) plus an additional 75 degrees turn.
  18. Install the EGR tube. Refer to TUBE, EXHAUST GAS RECIRCULATION (EGR), INSTALLATION .
    GC0146834Courtesy of CHRYSLER GROUP, LLC
  19. Install the fastener (1) securing the right high pressure tube to cylinder head cover and tighten to 11 N.m (8 ft. lbs.).
  20. Install the fastener (2) securing the left high pressure tube to EGR air flow control valve and tighten to 11 N.m (8 ft. lbs.).
    GC0146739Courtesy of CHRYSLER GROUP, LLC
  21. Connect the low pressure supply (2) and return (1) lines to the fuel injection pump.
    GC0146830Courtesy of CHRYSLER GROUP, LLC
  22. Connect the fuel quantity solenoid harness connector (3).
    GC0146780Courtesy of CHRYSLER GROUP, LLC
  23. Install the fuel injection pump blocker shield (1). Tighten the bolts (2) to 25 N.m (18 ft. lbs.).
    GC0146840Courtesy of CHRYSLER GROUP, LLC
  24. Using the (special tool #VM.10344, Tool, Oil Separator Remover/Installer) (2), Install the oil separator (1) onto the left intake camshaft and tighten to 30 N.m (22 ft. lbs.).
    GC0146774Courtesy of CHRYSLER GROUP, LLC
  25. Using a NEW  gasket (3), install the oil breather/camshaft seal housing (2). Tighten the bolts (1) to 14 N.m (10 ft. lbs.).
    GC0169759Courtesy of CHRYSLER GROUP, LLC
  26. Install the crankcase breather hose (4).
  27. Install the oil vapor pressure sensor (1). Refer to SENSOR, OIL VAPOR PRESSURE, INSTALLATION .
    GC0146589Courtesy of CHRYSLER GROUP, LLC
  28. Remove the (special tool #VM.10339, Tool, Crankshaft Timing) (1) from the starter side of the engine block.
    GC0146696Courtesy of CHRYSLER GROUP, LLC
  29. Install the engine block plug (1) and tighten to 30 N.m (22 ft. lbs.).
  30. Connect the negative battery cable.
  31. Start engine and check for leaks.
    GC0146436Courtesy of CHRYSLER GROUP, LLC
  32. Install the engine cover (1).
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