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Home >> Jeep >> 2017 >> Wrangler Sahara, Automatic Trans >> Repair and Diagnosis >> External Pages >> Different car >> Section 47 (Fuel System) >> Fuel Delivery, Diesel >> Pump, Fuel Injection, High Pressure >> Installation >> 2.0L Diesel

2.0L Diesel

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

Observe the following precautions when working on fuel systems: No sparks, open flames or smoking. Avoid inhaling and swallowing fuel. Avoid eye and skin contact with fuel. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing. Failure to observe these precautions may result in fire, explosion, property damage, and serious or fatal injury.

WARNING:

High pressure fuel lines deliver fuel under extreme pressure from the injection pump to the injectors. This maybe as high as 1600 bar (23, 206 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 high pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system.

CAUTION:

Cranking the engine for an extended time without a fuel supply may damage the fuel injection pressure pump.

NOTE:

The fuel injection pressure pump must not be disassembled or opened. The only serviceable items are the sprocket and the fuel quantity solenoid.

GC0148120Courtesy of CHRYSLER GROUP, LLC
  1. If removed, clean sealing surfaces and Install new O-ring seals onto the fuel quantity solenoid (1).
  2. If removed, install the fuel quantity solenoid (1) and securely tighten fasteners (2).
    GC0147918Courtesy of CHRYSLER GROUP, LLC
  3. Position the fuel injection pump to the back of the support with the pump shaft inserted through the drive sprocket and the pump housing engaged over the mounting studs on the support.
  4. Install the (special tool #20150, Remover/Installer, High Pressure Fuel Pump) Tool (1) onto the threaded end of the pump shaft enough to align the pin in the pump shaft with the keyway in the hub of the drive sprocket and tighten finger tight.
    GC0148123Courtesy of CHRYSLER GROUP, LLC
  5. Install the three nuts (1) securing the fuel injection pump (2) and tighten to the proper torque. Refer to TORQUE SPECIFICATIONS - 2.0L  .
    GC0147918Courtesy of CHRYSLER GROUP, LLC
  6. Remove the (Pump Rotation) (special tool #20150, Remover/Installer, High Pressure Fuel Pump) Tool (1) from the threaded end of the pump shaft.
    GC0147916Courtesy of CHRYSLER GROUP, LLC
  7. Install the nut (1) securing the sprocket to the fuel injection pump and tighten to the proper torque. Refer to TORQUE SPECIFICATIONS - 2.0L  .
  8. Remove the (special tool #20150, Remover/Installer, High Pressure Fuel Pump) (2).
    GC0148122Courtesy of CHRYSLER GROUP, LLC
  9. Install the coolant manifold (1) at intake manifold.
    GC0148121Courtesy of CHRYSLER GROUP, LLC
  10. Install the fuel return manifold (1) and securely tighten bolts (2).
  11. Connect the fuel return hose (3) to the fuel injection pump and tighten clamp.
  12. Connect the fuel injector return line to the fuel return manifold (1).
    GC0147915Courtesy of CHRYSLER GROUP, LLC
  13. Install the fuel injection pump guard (2) and securely tighten bolts (1).
  14. Attach the fuel supply line to the retainer clip.
    GC0159461Courtesy of CHRYSLER GROUP, LLC
  15. Connect the fuel supply line (2) and fuel return line (1) quick-connect fitting.
    GC0148119Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    High pressure fuel tubes from the fuel injection pressure pump to the fuel rail or from the fuel rail to the fuel injector must be replaced with new units if removed.

  16. Install new fuel tube (2) between the fuel injection pump (3) and the fuel rail (1). Tighten the union nuts to:
  17. Install the upper timing cover. Refer to the appropriate service information article. .
  18. Position the engine wire harness and attach the wire harness retainer to the upper timing cover.
    GC0147890Courtesy of CHRYSLER GROUP, LLC
  19. Connect the fuel quantity solenoid wire harness connector (2).
    GC0147935Courtesy of CHRYSLER GROUP, LLC
  20. Connect the boost pressure wire harness connector.
  21. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
  22. Install the right front wheelhouse splash shield. Refer to SHIELD, SPLASH, REAR WHEELHOUSE, INSTALLATION .
  23. Install the tire and wheel assembly.
  24. Install the belly pan. Refer to BELLY PAN, INSTALLATION .
  25. Remove the support and lower the vehicle.
    GC0157479Courtesy of CHRYSLER GROUP, LLC
  26. Fill the cooling system. Refer to STANDARD PROCEDURE .
  27. Connect the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), connect the IBS connector to the negative battery cable.
  28. Start the engine and inspect the fuel connections for leaks.
  29. Install the engine cover (1).
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