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Home >> Chrysler >> 2011 >> 300 C, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1580 (Fuel System - 2500 Hd) >> Fuel Delivery, 6.7L Diesel >> Pump, Fuel Injection >> Installation

Pump, Fuel Injection: Installation

WARNING: This page is about a different car, the 2017 RAM 2500 HD. However, it is still accessible from the selected car via links, so may be relevant.
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.

GC0108808Courtesy of CHRYSLER GROUP, LLC
  1. Inspect the pump mounting surfaces at pump and mounting flange and pilot bore for nicks, cuts or damage. Inspect O-ring surfaces for nicks, cuts or damage.
  2. Clean the injection pump mounting flange and pilot bore at gear housing. Also clean the front of injection pump.
  3. Install a new rubber O-ring (square) (4) into machined groove at pump mounting area.
  4. Apply clean engine oil to injection pump O-ring and pilot bore only. 

    The machined tapers on both injection pump shaft and injection pump gear must be absolutely dry, clean and free of any dirt or oil film. This will ensure proper gear-to-shaft tightening. 

  5. Clean the pump gear and pump shaft at machined tapers with an evaporative type cleaner such as brake cleaner.
    GC0108809Courtesy of CHRYSLER GROUP, LLC
  6. FUEL INJECTION PUMP PHASING:  Perform the following phasing procedure anytime the injection pump has been removed and reinstalled.
  7. Locate the end of the fuel injection pump shaft (2). Two numbers (750 or 754 and 0) are stamped into the end of the shaft.
    GC0108810Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Fuel Injection Pump used for illustration has number 750.

  8. Rotate the injection pump shaft until the number 5 (located in the center of number 750 or 754) is positioned at 9 o'clock (1).
  9. Position the injection pump to mounting flange on gear housing while aligning injection pump shaft through back of injection pump gear. Be sure the number 5 is still at the 9 o'clock position (1).
  10. Bring the engine to TDC position. Do this by rotating the crankshaft until the TDC mark on the crankshaft damper is at 12 o'clock position. It does not matter if cylinder No. 1 or No. 6 is at TDC. Again, check to be sure the number 5 is still at the 9 o'clock position (1). Rotate pump shaft accordingly.
    GC0108808Courtesy of CHRYSLER GROUP, LLC
  11. After the pump is positioned flat to mounting flange, install three pump mounting nuts (6) and tighten finger tight only.  Do not attempt a final tightening at this time. Do not attempt to tighten (pull) pump to gear housing using mounting nuts. Damage to pump or gear housing may occur. The pump must be positioned flat to its mounting flange before attempting to tighten three mounting nuts. 
  12. To prevent damage or cracking of components, install and tighten nuts in the following sequence:
    1. Install the fuel injection pump shaft washer and nut to pump shaft. Tighten the nut finger tight only. 
    2. Do a preliminary (light) tightening of fuel injection pump shaft nut (1).
    3. Tighten the three fuel injection pump mounting nuts to 24 N.m (18 ft. lbs.).
    4. Do a final tightening of fuel injection pump shaft nut (1) to 105 N.m (77 ft. lbs.).
    GC0108811Courtesy of CHRYSLER GROUP, LLC
  13. Using a 3/8" drive ratchet, install the drive gear access cover (2). Tighten the cover to 8 N.m (71 in. lbs.).
    GC0155150Courtesy of CHRYSLER GROUP, LLC
  14. Install the high-pressure pump-to-fuel rail fuel tube (5) and tighten union nuts to 40 N.m (30 ft. lbs.).
    GC0108630Courtesy of CHRYSLER GROUP, LLC
  15. Install the fuel return line. Tighten the banjo bolt (2) to 24 N.m (18 ft. lbs.).
  16. Install the quick-connect fitting (4).
  17. Install the clamp (5).
  18. Connect the Fuel Control Actuator (FCA) wire harness connector (6) to rear of injection pump.
  19. Install the accessory drive belt. Refer to BELT, SERPENTINE, INSTALLATION .
  20. Install the viscous cooling fan. Refer to FAN, COOLING, VISCOUS, INSTALLATION .
    GC0108812Courtesy of CHRYSLER GROUP, LLC
  21. Install the Charge Air Cooler (CAC) tube (3) Tighten clamps (4) to 14 N.m (124 in. lbs.).
    GC0108506Courtesy of CHRYSLER GROUP, LLC
  22. Install the CCV oil drains hoses (3) to the cylinder head cover.
    GC0155340Courtesy of CHRYSLER GROUP, LLC
  23. Disconnect both fuel injector wire harness connectors (1).
    GC0157561Courtesy of CHRYSLER GROUP, LLC
  24. Install the fuel tube silencer (1).
    GC0110278Courtesy of CHRYSLER GROUP, LLC
  25. Connect the crankcase pressure sensor 1 wire harness connectors (7).
    GC0155113Courtesy of CHRYSLER GROUP, LLC
  26. Connect the crankcase pressure sensor 2 wire harness connector (1).
    GC0155426Courtesy of CHRYSLER GROUP, LLC
  27. Connect the EGR cooler bypass valve wire harness connector (1).
  28. Connect the exhaust pressure sensor wire harness connector (2).
    GC0155445Courtesy of CHRYSLER GROUP, LLC
  29. Position the bulk head connector (1) and install a new cable tie to secure connector.
    GC0161582Courtesy of CHRYSLER GROUP, LLC
  30. Install the engine cover (3). Tighten bolts (1) to 10 N.m (89 in. lbs.).
  31. Install the oil dipstick (2).
  32. Connect both negative battery cables.
  33. Check system for fuel or engine oil leaks.
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