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Removal And Installation

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CAUTION:

Do not rotate the crankshaft using the damper bolt. The bolt has left-hand threads and can be inadvertently loosened resulting in loss of camshaft timing. Only rotate the damper itself in a clockwise direction (as viewed from the front).

NOTE:

The "GSE INJECTOR ADAPTATION" scan tool procedure should always be run after a PCM, fuel injector, fuel rail, high pressure pump or fuel pressure sensor is replaced. The procedures should be in the "Miscellaneous Functions" tab in the PCM. Failure to run the procedures may cause DTCs to set in the PCM.

REMOVAL 

  1. Perform the fuel pressure release procedure. Refer to FUEL DELIVERY, STANDARD PROCEDURE .
  2. Disconnect and isolate the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), disconnect the IBS connector first before disconnecting the negative battery cable.
  3. Remove the engine cover. Refer to COVER, ENGINE, REMOVAL AND INSTALLATION .
  4. Remove the air cleaner body. Refer to BODY, AIR CLEANER, REMOVAL AND INSTALLATION .
  5. Remove the battery tray. Refer to TRAY, BATTERY, REMOVAL AND INSTALLATION .
    GC0189890Courtesy of CHRYSLER GROUP, LLC
  6. Using the (special tool #2069100090, Holder, Front Damper 3 Pin) (1), rotate the crankshaft clockwise (as viewed from the front) and position the number 1 cylinder piston 90 degrees from top-dead-center (TDC) to place the camshaft between pump cam lobes (zero lift). This will relieve pressure from the pump roller tappet.
    GC0189496Courtesy of CHRYSLER GROUP, LLC
  7. Thoroughly clean the area around the fuel line nuts to prevent contaminates from entering the fuel system.
  8. Loosen the fuel line nuts (1, 2a) and remove the high pressure fuel line (2b).
    NOTE:

    The high pressure fuel line can be reused if the injection pump and fuel rail are being reused, otherwise the high pressure fuel line must be discarded and replaced.

    GC0189956Courtesy of CHRYSLER GROUP, LLC
  9. Disconnect the fuel supply line (1) from the injection pump.
  10. Unlock and disconnect the wire harness connector (2) from the injection pump.
    GC0190046Courtesy of CHRYSLER GROUP, LLC
  11. Unlock and disconnect the coolant temperature sensor wire harness connector (1).
    GC0189976Courtesy of CHRYSLER GROUP, LLC
  12. To avoid side loading damage to the pump, remove the bolts (1a) at the same time, or in alternating one half turn increments and remove the fuel injection pump (1b) complete with roller tappet (1c).

INSTALLATION 

  1. Lubricate the outside diameter of the roller tappet and the inside of the roller tappet bore in the cylinder head with engine oil.
    GC0189879Courtesy of CHRYSLER GROUP, LLC
  2. Install the injection pump (1a) complete with roller tappet (1b) onto the cylinder head. To avoid side loading damage to the pump, tighten the bolts (1c) at the same time, or in alternating one half turn increments to the proper torque specifications. Refer to FUEL DELIVERY, TECHNICAL SPECIFICATIONS .
    NOTE:

    The side anti-rotation roller (a) must be inserted in the groove on the cylinder head.

    GC0190046Courtesy of CHRYSLER GROUP, LLC
  3. Connect and lock the coolant temperature sensor wire harness connector (1).
    GC0189956Courtesy of CHRYSLER GROUP, LLC
  4. Connect and lock the injection pump wire harness connector (2).
  5. Install the fuel supply line (1) to the injection pump.
    GC0189496Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The high pressure fuel line can be reused if the injection pump and fuel rail are being reused, otherwise the high pressure fuel line must be discarded and replaced.

  6. Lightly lubricate the fuel line nuts with clean engine oil.
  7. Install the fuel line (2b) and tighten the fuel line nuts (1, 2a) to the proper torque specifications. Refer to FUEL DELIVERY, TECHNICAL SPECIFICATIONS .
  8. Install the battery tray. Refer to TRAY, BATTERY, REMOVAL AND INSTALLATION .
  9. Install the air cleaner body. Refer to BODY, AIR CLEANER, REMOVAL AND INSTALLATION .
  10. Install the engine cover. Refer to COVER, ENGINE, REMOVAL AND INSTALLATION .
  11. Connect the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), connect the IBS connector.
  12. Check the high pressure fuel system for leaks. Refer to FUEL DELIVERY, DIAGNOSIS AND TESTING .
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