Liberty, Wrangler 2006-2007

Injection Pump

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
    CAUTION
    High pressure lines deliver diesel fuel under extreme pressure from the injection pump to the fuel injectors. This may be as high as 23,200 psi.(1600 bar). 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. Wear safety goggles and adequate protective clothing when servicing fuel system.

  2.  
  3. Disconnect negative battery cable.
  4.  
  5. Remove engine cover and bracket.
  6.  
  7. Evacuate A/C system.
  8.  
  9. Remove accessory drive belt.
  10.  
  11. Remove cooling fan and fan shroud.
  12.  
  13. Remove charge air cooler outlet hose to intake manifold.
  14.  
  15. Remove fan support assembly.
  16.  
  17. Remove timing belt outer cover.
  18.  
  19. Using special tool VM.1055, remove high pressure injection pump sprocket retaining nut.
    NOTE
    The use of special tool VM.1067 will allow you to remove the high pressure injection pump without removing the timing belt from the engine. This will allow you to remove and install the high pressure injection pump without altering injection pump timing.

  20.  
  21. Install feet from VM.1067 in injection pump sprocket as shown.
  22.  
  23. Install inner flange of special tool VM.1067 on injection pump sprocket as shown. Secure flange to feet in injection pump sprocket with Allen bolts supplied with tool.
  24.  
  25. Screw the high pressure injection pump sprocket holding plate assembly into flange of VM.1067. Using left hand threaded bolt supplied, secure holding plate assembly to timing belt inner cover.
  26.  
  27. Disconnect A/C lines at compressor.
  28.  
  29. Remove charge air inlet hose.
  30.  
  31. Remove the EGR airflow control valve from the intake manifold.
  32.  
  33. Remove high pressure injection pump to fuel rail high pressure line.
  34.  
  35. Disconnect high pressure injection pump quantity control valve electrical connector.
  36.  
  37. Disconnect fuel supply and return lines at high pressure injection pump.
  38.  
  39. Remove alternator to intake manifold bracket.
    WARNING
    Care must be taken not to bend the brake vacuum tube when removing high pressure pump.

  40.  
  41. Remove high pressure injection pump retaining nuts and remove pump.

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    Fig. Fuel injection pump-2.8L diesel



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    Fig. Injection pump sprocket retaining nut removal-2.8L diesel



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    Fig. Special tool feet installation-2.8L diesel



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    Fig. Special tool installation-2.8L diesel



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    Fig. Injection pump removal-2.8L diesel



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    Fig. Injection pump gear removal-2.8L diesel

  42.  

To install:

  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.  
  3. Install high pressure injection pump retaining nuts. Torque nuts to 20 ft. lbs. (27 Nm).
  4.  
  5. Unscrew injection pump holding plate (part of VM.1067) from inner timing belt cover and remove.
  6.  
  7. Install high pressure injection pump sprocket retaining nut to hold sprocket in place.
  8.  
  9. Remove flange and feet (both part of VM.1067) from high pressure injection pump sprocket.
  10.  
  11. Using special tool VM.1055, torque high pressure injection pump sprocket retaining nut to 65 ft. lbs. (88 Nm).
  12.  
  13. Connect fuel quantity control valve electrical connector.
  14.  
  15. Connect fuel supply and return lines at high pressure injection pump.
  16.  
  17. Install the EGR airflow control valve.
  18.  
  19. Install outer timing belt cover.
  20.  
  21. Install fan support assembly.
  22.  
  23. Install accessory drive belt.
  24.  
  25. Install cooling fan and shroud assembly.
  26.  
  27. Install charge air cooler outlet hose.
  28.  
  29. Install engine cover and bracket.
  30.  
  31. Connect negative battery cable.
  32.  
  33. Evacuate and recharge A/C system.
  34.  

 
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