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Home >> Jeep >> 2017 >> Wrangler Rubicon, Automatic Trans >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Fuel System >> Fuel Delivery, Diesel >> Pump, Fuel Injection >> Removal

Pump, Fuel Injection: Removal

CAUTION:

Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only.

WARNING:

High-pressure lines deliver diesel fuel under extreme pressure from the injection pump to the fuel injectors. 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. 

  1. Disconnect the negative battery cable.
  2. Center and lock the steering wheel.
  3. Remove the four nuts and the engine cover.
  4. Raise and support vehicle. Refer to HOISTING, STANDARD PROCEDURE .
  5. Remove the front lower splash shield.
  6. Drain the cooling system. Refer to DRAINING .
  7. Remove the two oil cooler return tube bolts.
  8. Remove the left wheel house splash shield. Refer to SHIELD, SPLASH, WHEELHOUSE, REMOVAL .
  9. Remove the lower intermediate steering shaft-to-upper intermediate shaft pinch bolt and disconnect the intermediate shaft.
    GC0148215Courtesy of CHRYSLER GROUP, LLC
  10. Remove the oil cooler return hose (1) at water pump inlet tube.
  11. Remove the thermostat housing. Refer to THERMOSTAT, REMOVAL .
  12. Remove the water inlet elbow. Refer to TUBE, WATER INLET, REMOVAL .
  13. Remove the air cleaner body. Refer to BODY, AIR CLEANER, REMOVAL .
  14. Disconnect the coolant reservoir hose at radiator.
  15. Disconnect the upper radiator hose at radiator.
  16. Remove the cooling fan. Refer to FAN, COOLING, REMOVAL .
  17. Remove the serpentine belt. Refer to BELT, SERPENTINE, REMOVAL .
  18. Disconnect the Charge Air Cooler (CAC) outlet hose from the EGR air flow control valve.
  19. Disconnect the EGR air flow control valve harness connector.
  20. Remove the generator. Refer to GENERATOR, REMOVAL .
  21. Remove the timing belt. Refer to the appropriate service information.
    GC0145381Courtesy of CHRYSLER GROUP, LLC
  22. Using (special tool #VM.1055, Locking Tool) (1), remove the injection pump sprocket nut (2).
  23. Attach a (special tool #1023, Puller) and remove sprocket from pump.
    GC0085629Courtesy of CHRYSLER GROUP, LLC
  24. Install the accessory drive idler pulley bracket (1). Tighten the bolts finger tight.
  25. Install the front engine lift bracket (2). Tighten the bolts finger tight.
  26. Remove the right side and left side lower engine mount nuts.
  27. Install the (special tool #8534C, Fixture, Driveline Support).
  28. Raise the engine.
  29. Remove the high pressure feed tube at fuel rail.
  30. Remove the bolt securing the high pressure feed tube to intake manifold.
    GC0145402Courtesy of CHRYSLER GROUP, LLC
  31. Disconnect the low pressure supply (2) and return (1) lines from the fuel injection pump.
    GC0148216Courtesy of CHRYSLER GROUP, LLC
  32. Detach the fuel line routing clip at the left engine mount bracket.
  33. Disconnect the fuel quantity solenoid wire harness connector.
  34. Remove the four bolts (1) and the left engine mount and bracket.
    GC0145382Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Fuel quantity solenoid removed for clarity.

  35. Remove the high-pressure fuel line (1) from the rear of the fuel injection pump and the fuel rail.
    GC0145422Courtesy of CHRYSLER GROUP, LLC
  36. Remove the nuts (8) and the blocker plate (7).
  37. Remove the nuts (6) and fuel injection pump (5).
  38. If necessary, Remove the banjo bolts (1) and the fuel supply (3) and the return (4) fittings from the fuel injection pump (5).
    GC0145378Courtesy of CHRYSLER GROUP, LLC
  39. If necessary, remove the screws (3) and the fuel quantity solenoid (2).
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