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Home >> Chrysler >> 2011 >> 300 C, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1580 (Fuel System - 2500 Hd) >> Fuel Delivery, 6.7L Diesel >> Pump, Fuel Injection >> Removal

Pump, Fuel Injection: Removal

WARNING: This page is about a different car, the 2017 RAM 2500 HD. However, it is still accessible from the selected car via links, so may be relevant.
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.

GC0161582Courtesy of CHRYSLER GROUP, LLC
  1. Disconnect and isolate both of the negative battery cables.
  2. Remove the oil dipstick (2).
  3. Remove bolts (1) and the engine cover (3).
    GC0155445Courtesy of CHRYSLER GROUP, LLC
  4. Cut the cable tie and position aside the bulk head connector (1).
    GC0155426Courtesy of CHRYSLER GROUP, LLC
  5. Disconnect the exhaust pressure sensor wire harness connector (2).
  6. Disconnect the EGR cooler bypass valve wire harness connector (1).
    GC0155113Courtesy of CHRYSLER GROUP, LLC
  7. Disconnect the crankcase pressure sensor 2 wire harness connector (1).
    GC0110278Courtesy of CHRYSLER GROUP, LLC
  8. Disconnect the crankcase pressure sensor 1 wire harness connectors (7).
    GC0157561Courtesy of CHRYSLER GROUP, LLC
  9. Remove the fuel tube silencer (1).
    GC0155340Courtesy of CHRYSLER GROUP, LLC
  10. Disconnect both fuel injector wire harness connectors (1).
    GC0108506Courtesy of CHRYSLER GROUP, LLC
  11. Remove the CCV oil drains hoses (3) from cylinder head cover.
    GC0108803Courtesy of CHRYSLER GROUP, LLC
  12. Remove the viscous cooling fan. Refer to FAN, COOLING, VISCOUS, REMOVAL .
  13. Remove the accessory drive belt. Refer to BELT, SERPENTINE, REMOVAL .
    GC0108804Courtesy of CHRYSLER GROUP, LLC
  14. Thoroughly clean rear of injection pump, and attachment points for its fuel lines. Also clean the opposite ends of these same lines at their attachment points.
  15. Disconnect quick-connect fitting by pressing on button (1).
    CAUTION:

    Whenever a fuel line fitting is connected to a secondary fitting, always use a back-up wrench on the secondary fitting. Do not allow the secondary fitting to rotate.

  16. Remove banjo bolt (2).
  17. Disconnect FCA (Fuel Control Actuator) wire harness connector (3).
    GC0108630Courtesy of CHRYSLER GROUP, LLC
  18. Remove line clamp (5).
    GC0155150Courtesy of CHRYSLER GROUP, LLC
  19. Remove the high pressure pump-to-fuel rail fuel tube (5).
    GC0108805Courtesy of CHRYSLER GROUP, LLC
  20. Remove fuel pump drive gear access cover with a 3/8" drive ratchet. Access cover (2) is threaded to timing gear cover.
  21. Remove fuel pump drive gear mounting nut and washer.
    GC0108806Courtesy of CHRYSLER GROUP, LLC
  22. Attach C3428B, or (special tool #L-4407A, Puller, Gear) (or equivalent) gear puller (1) to pump drive gear with 2 bolts, and separate gear from pump (a keyway is not used on this particular injection pump). Leave drive gear hanging loose within timing gear cover.
    GC0108807Courtesy of CHRYSLER GROUP, LLC
  23. Remove three injection pump mounting nuts (6), and remove pump from engine.
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