Fuel Injection Pump: Removal
WARNING: This page is about a different car, the 2005 Jeep Liberty. However, it is still accessible from the selected car via links, so may be relevant.
WARNING:
HIGH - PRESSURE LINES DELIVER DIESEL FUEL UNDER EXTREME PRESSURE FROM THE INJECTION PUMP TO THE FUEL INJECTORS. THIS MAY BE AS HIGH AS 1600BAR (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.
- Disconnect negative battery cable.
- Remove engine cover and bracket (Refer to ENGINE - REMOVAL) or (Refer to ENGINE - REMOVAL) or (Refer to ENGINE - REMOVAL) .
- Evacuate A/C system (Refer to HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE) .
- Remove accessory drive belt (Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL) .
- Remove cooling fan and fan shroud.
- Remove charge air cooler outlet hose to intake manifold.
- Remove fan support assembly (Refer to COOLING/ENGINE/RADIATOR FAN - REMOVAL) .
- Remove timing belt outer cover (Refer to ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) or (Refer to ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) or (Refer to ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).
- Using special tool VM.1055, remove high pressure injection pump sprocket retaining nut. See Fig 1.
1 - IDLER PULLEY 2 - TIMING BELT 3 - VM.1055 4 - INJECTION PUMP SPROCKET 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. - Install feet from VM.1067 in injection pump sprocket as shown. See Fig 2.
1 - OUTER TIMING BELT SEALING SURFACE 2 - TIMING BELT 3 - TIMING BELT SPROCKET 4 - FEET FOR SPECIAL TOOL VM.1067 5 - INNER TIMING BELT COVER - Install inner flange of special tool VM.1067 on injection pump sprocket as shown. See Fig 3. Secure flange to feet in injection pump sprocket with allen bolts supplied with tool.
1 - TIMING BELT 2 - INJECTION PUMP SPROCKET 3 - FLANGE OF VM.1067 4 - INNER TIMING BELT COVER - 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. See Fig 4.
1 - TIMING BELT 2 - INNER TIMING BELT COVER 3 - INJECTION PUMP SPROCKET HOLDING PLATE ASSEMBLY PART OF VM.1067 4 - INJECTION PUMP SPROCKET - Disconnect A/C lines at compressor.
- Remove charge air inlet hose.
- Remove the EGR airflow control valve from the intake manifold (Refer to EMISSIONS CONTROL/EXHAUST GAS RECIRCULATION/VALVE - REMOVAL) .
- Remove high pressure injection pump to fuel rail high pressure line.
- Disconnect high pressure injection pump quantity control valve electrical connector.
- Disconnect fuel supply and return lines at high pressure injection pump. See Fig 5.
- Remove alternator to intake manifold bracket.CAUTION: Care must be taken not to bend the brake vacuum tube when removing high pressure pump.
- Remove high pressure injection pump retaining nuts and remove pump. See Fig 5.
| 1 - BANJO FITTING |
| 2 - BRASS WASHERS |
| 3 - FUEL INLET LINE |
| 4 - FUEL OUTLET LINE |
| 5 - BANJO FITTING |
| 6 - INJECTION PUMP RETAINING NUT |
| 7 - INJECTION PUMP |
| 8 - MOUNTING STUDS |
| 9 - INNER TIMING COVER SEAL |
| 10 - INNER TIMING COVER |
| 11 - RETAINING BOLT |
| 12 - RETAINING BOLT |
| 13 - RETAINING BOLT |
| 14 - HOSE CLAMP |
| 15 - CYLINDER HEAD COVER/INTAKE MANIFOLD |
| 16 - FUEL RETURN LINE TO INJECTION PUMP |
| 17 - HOSE CLAMP |
| 18 - FUEL RETURN JUNCTION BLOCK RETAINING BOLT |
| 19 - FUEL RETURN JUNCTION BLOCK |