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Pump-High Pressure Fuel: Removal

WARNING: This page is about a different car, the 2006 Dodge Magnum, 2006 Dodge Charger, and 2006 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: High pressure fuel lines deliver diesel fuel under extreme pressure from the injection pump to the fuel injectors. This may be as high as 1600 bar (23,200 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 for high pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system.
Fig 1: High Pressure Pump Removal/Installation
GC0039503Courtesy of DAIMLERCHRYSLER CORP.
  1. Remove engine cover.
  2. Remove negative battery cable.
  3. Release fuel pressure.
  4. Remove high pressure line support bracket.
  5. Remove high pressure line retaining nut. See Fig 1.
    Fig 2: Fuel Line Pliers
    GC0039504Courtesy of DAIMLERCHRYSLER CORP.
  6. Remove the return line clamp using Fuel Line Pliers 9539.
  7. Remove the inlet supply clamp using Fuel Line Pliers 9539.
  8. Remove both rubber lines at the pump.
  9. Disconnect the pump electrical connectors.
  10. Remove the pump mounting bolts.
  11. Remove the pump assembly.
CAUTION: Do not crimp or bend fuel line. Capture all fluids that flow out of connections.
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