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Pump, Fuel Injection: Installation: Installation

WARNING: This page is about a different car, the 2012 RAM Pickup and 2012 RAM Cab & Chassis. 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.

Fig 1: Fuel Injection Pump & Mounting Components
GC0108808Courtesy of CHRYSLER GROUP, LLC
1 - PUMP DRIVE GEAR NUT
2 - WASHER
3 - PUMP DRIVE GEAR
4 - RUBBER O-RING
5 - FUEL INJECTION PUMP
6 - PUMP MOUNTING NUTS (3)
7 - PUMP MOUNTING STUDS (3)
8 - O-RING MACHINED GROOVE
9 - FRONT TIMING GEAR HOUSING
  1. Inspect 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 injection pump mounting flange and pilot bore at gear housing. Also clean front of injection pump.
  3. Install 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 pump gear and pump shaft at machined tapers with an evaporative type cleaner such as brake cleaner.
    Fig 2: Injection Pump Shaft Phasing Marks
    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.
    Fig 3: Injection Pump Shaft Position
    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 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.
    Fig 4: Fuel Injection Pump & Mounting Components
    GC0108808Courtesy of CHRYSLER GROUP, LLC
    1 - PUMP DRIVE GEAR NUT
    2 - WASHER
    3 - PUMP DRIVE GEAR
    4 - RUBBER O-RING
    5 - FUEL INJECTION PUMP
    6 - PUMP MOUNTING NUTS (3)
    7 - PUMP MOUNTING STUDS (3)
    8 - O-RING MACHINED GROOVE
    9 - FRONT TIMING GEAR HOUSING
  11. After 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 injection pump shaft washer and nut to pump shaft. Tighten nut finger tight only. 
    2. Do preliminary (light) tightening of injection pump shaft nut (1).
    3. Tighten three injection pump mounting nuts to 24 N.m (18 ft. lbs.).
    4. Do a final tightening of pump shaft nut (1) to 105 N.m (77 ft. lbs.).
    Fig 5: Pump Drive Gear Access Cover
    GC0108811Courtesy of CHRYSLER GROUP, LLC
    1 - FRONT TIMING GEAR COVER
    2 - GEAR ACCESS PLATE (COVER)
    3 - SQUARE DRIVE (FOR COVER REMOVAL/INSTALLATION)
  13. Install drive gear access cover (2) using a 3/8" drive ratchet. Access cover is threaded to timing gear cover. Tighten to 8 N.m (71 in. lbs.).
    Fig 6: Fuel Injection Pump Components
    GC0108630Courtesy of CHRYSLER GROUP, LLC
  14. Install fuel return line. Tighten banjo bolt (2) to 24 N.m (18 ft. lbs.).
  15. Install quick-connect fitting (4).
  16. Install fuel line (injection pump-to-fuel rail). Using a back up wrench, tighten fitting at fuel pump to 40 N.m (30 ft. lbs.). Tighten fitting at fuel rail to 40 N.m (30 ft. lbs.).
  17. Install clamp (5).
  18. Connect Fuel Control Actuator (FCA) electrical connector (6) to rear of injection pump.
    Fig 7: Intake Tube & Connecting Hose
    GC0108812Courtesy of CHRYSLER GROUP, LLC
    1 - MANIFOLD ABOVE HEATERS
    2 - RUBBER CONNECTING HOSE
    3 - METAL INTAKE TUBE
    4 - CLAMPS (2)
  19. Install rubber intake manifold air intake tube (2). Tighten clamps (4).
  20. Install accessory drive belt.
  21. Connect both negative battery cables.
  22. Check system for fuel or engine oil leaks.
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