Fuel Injection Pump

WARNING: This page is about a different car, the 2007 Chrysler PT Cruiser. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: High-pressure fuel lines deliver fuel under extreme pressure from the injection pump to the injectors. This maybe as high as 1600bar (23,200psi). 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.

Fig 1: Battery Location

Courtesy of CHRYSLER LLC

1 - BATTERY

2 - PASSENGER SEAT

Disconnect negative battery (1) cable located under passenger seat.

Remove engine cover.

Fig 2: Air Cleaner Housing Assembly

Courtesy of CHRYSLER LLC

1 - TURBOCHARGER INLET HOSE

2 - MAF SENSOR RETAINING BOLT

3 - MAF SENSOR

4 - O-RING

5 - MAF SENSOR ELECTRICAL CONNECTOR

6 - AIR CLEANER ASSEMBLY

7 - INLET DUCT

8 - AIR CLEANER HOUSING ASSEMBLY BRACKET

Disconnect MAF sensor (3) electrical connector.
Disconnect air inlet hose (7) and turbocharger inlet hose (1) from air cleaner housing (6).

Remove air cleaner housing (6) assembly by pulling straight up out of mounts. Refer to HOUSING-AIR CLEANER .

Fig 3: Injection Pump Fuel Lines

Courtesy of CHRYSLER LLC

1 - RETURN LINE FROM FUEL RAIL

2 - INJECTION PUMP FEED LINE

3 - INJECTION PUMP

4 - HIGH PRESSURE LINE TO FUEL RAIL

Remove fuel line retainer and retaining bolt from pump (3). Disconnect fuel supply (2) and return lines (1) at pump. See Fig 3.

Disconnect high pressure fuel line (4) from pump to rail at injection pump. See Fig 3.

Fig 4: Injection Pump Retaining Bolts

Courtesy of CHRYSLER LLC

1 - INJECTION PUMP

2 - INJECTION PUMP RETAINING BOLTS

3 - HIGH PRESSURE LINE TO FUEL RAIL

Remove injection pump retaining bolts (2) and remove pump (1) from cylinder head. See Fig 4.