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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 >> 2.2L Diesel

2.2L 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.

GC0177006Courtesy of CHRYSLER GROUP, LLC
  1. If removed, clean sealing surfaces and Install NEW  O-ring seals onto the fuel quantity solenoid (2).
  2. If removed, install the fuel quantity solenoid (2) and securely tighten the fasteners (1).
    GC0175369Courtesy of CHRYSLER GROUP, LLC
  3. Position the fuel injection pump to the back in position, taking care to insert the pin (1a) on the drive shaft in the groove (1b) on the toothed pulley.
    GC0175366Courtesy of CHRYSLER GROUP, LLC
  4. Install the three NEW  nuts (1) securing the fuel injection pump (2) and tighten to the proper torque. Refer to TORQUE SPECIFICATIONS  .
    GC0176889Courtesy of CHRYSLER GROUP, LLC
  5. Install the nut securing the sprocket to the fuel injection pump and tighten to the proper torque. Refer to TORQUE SPECIFICATIONS  .
    GC0176944Courtesy of CHRYSLER GROUP, LLC
  6. Remove the bolts (1), the nuts (3) and the (special tool #2029900090, Remover, Pressure Pump Pulley) tool (2).
    GC0176976Courtesy of CHRYSLER GROUP, LLC
  7. Remove screw the pins (2) and the (special tool #2029900090, Remover, Pressure Pump Pulley) locking ring (1).
    GC0177037Courtesy of CHRYSLER GROUP, LLC
  8. Install the right side Power Distribution Center (PDC) with mounting bracket (2) and securely tighten the nuts (1).
    GC0177079Courtesy of CHRYSLER GROUP, LLC
  9. Reposition the wire harness (2) and attach the wire harness retainers (1).
    GC0147915Courtesy of CHRYSLER GROUP, LLC
  10. Install the fuel injection pump guard (2) and securely tighten the bolts (1).
    GC0177005Courtesy 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.

  11. Install the NEW  fuel tube (2) between the fuel injection pump and the fuel rail. Tighten the union nuts (1, 3) to:
    • Step 1 Tighten the union nut (1) at fuel rail to the proper torque. Refer to TORQUE SPECIFICATIONS  .
    • Step 2 Using a wrench to counter hold fitting, tighten union nut (3) at the fuel injection pump to the proper torque. Refer to TORQUE SPECIFICATIONS  .
    GC0169944Courtesy of CHRYSLER GROUP, LLC
  12. Install the fuel injection pump insulator (1).
    GC0177070Courtesy of CHRYSLER GROUP, LLC
  13. Install the fuel return manifold (2) and securely tighten the bolts (1).
    GC0175370Courtesy of CHRYSLER GROUP, LLC
  14. Install the fuel return hose (3) to the fuel injection pump and engage the clamp.
  15. Connect the fuel supply line (2) quick-connect fitting to the fuel injection pump.
  16. Connect the fuel quantity solenoid wire harness connector (1).
    GC0177029Courtesy of CHRYSLER GROUP, LLC
  17. Install the fuel return line (1) from fuel manifold.
    GC0176945Courtesy of CHRYSLER GROUP, LLC
  18. Install the bolt (3) securing the coolant tube and securely tighten.
  19. Install the eyelet bracket (1) and securely tighten the bolt (2).
  20. Install the upper timing cover. Refer to the appropriate service information article. .
  21. Install the air cleaner body. Refer to BODY, AIR CLEANER, INSTALLATION .
  22. Connect the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), connect the IBS connector to the negative battery cable.
  23. Start the engine and inspect the fuel connections for leaks.
  24. Install the engine cover. Refer to the appropriate service information article. .
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