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Fuel Injection Pump: Installation

WARNING: This page is about a different car, the 2005 Jeep Liberty. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: HIGH - PRESSURE LINES DELIVER DIESEL FUEL UNDER EXTREME PRESSURE FROM THE INJECTION PUMP TO THE FUEL INJECTORS. THIS MAY BE AS HIGH AS 1600BAR (23,200 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  (Refer to FUEL SYSTEM/FUEL DELIVERY - DIAGNOSIS AND TESTING)  . WEAR SAFETY GOGGLES AND ADEQUATE PROTECTIVE CLOTHING WHEN SERVICING FUEL SYSTEM. 
NOTE: If Engine Timing Is Of Concern, (Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION) , (Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION) , (Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION) or (Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN TENSIONER & PULLEY - ADJUSTMENTS) .
  1. Loosen bolt in center of injection pump holding plate and slide high pressure injection pump through the accessory bracket into the injection pump sprocket.
  2. Install high pressure injection pump retaining nuts. See Figure. Torque nuts to 27.5N.m (20 ft. lbs.).
  3. Unscrew injection pump holding plate (part of VM.1067) from inner timing belt cover and remove. See Figure.
  4. Install high pressure injection pump sprocket retaining nut to hold sprocket in place.
  5. Remove flange and feet (both part of VM.1067) from high pressure injection pump sprocket. See Figure. See Figure.
  6. Using special tool VM.1055, torque high pressure injection pump sprocket retaining nut to 88.3N.m.(65 ft.lbs.). See Figure.
  7. Connect fuel quantity control valve electrical connector.
  8. Connect fuel supply and return lines at high pressure injection pump. See Figure. (Refer to WARNING ).
  9. Install the EGR airflow control valve (Refer to EMISSIONS CONTROL/EXHAUST GAS RECIRCULATION/VALVE - INSTALLATION) .
  10. Install outer timing belt cover (Refer to ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) , (Refer to ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) and (Refer to ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION) .
  11. Install fan support assembly (Refer to COOLING/ENGINE/RADIATOR FAN - INSTALLATION) .
  12. Install accessory drive belt (Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION) .
  13. Install cooling fan and shroud assembly.
  14. Install charge air cooler outlet hose.
  15. Install engine cover and bracket (Refer to ENGINE - INSTALLATION) , (Refer to ENGINE - INSTALLATION) and (Refer to ENGINE - INSTALLATION) .
  16. Connect negative battery cable.
  17. Evacuate and recharge A/C system (Refer to HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE) .
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