LEMON Manuals: Even more car manuals for everyone
Home >> Jeep >> 2017 >> Wrangler Sahara, Automatic Trans >> Repair and Diagnosis >> External Pages >> Different car >> Section 47 (Fuel System) >> Fuel Delivery, Diesel >> Pump, Fuel Injection, High Pressure >> Removal >> 2.0L Diesel

2.0L Diesel

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

Observe the following precautions when working on fuel systems: No sparks, open flames or smoking. Avoid inhaling and swallowing fuel. Avoid eye and skin contact with fuel. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing. Failure to observe these precautions may result in fire, explosion, property damage, and serious or fatal injury.

WARNING:

High pressure fuel lines deliver fuel under extreme pressure from the injection pump to the injectors. This maybe as high as 1600 bar (23, 206 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 high pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system.

CAUTION:

Cranking the engine for an extended time without a fuel supply may damage the fuel injection pressure pump.

NOTE:

The fuel injection pressure pump must not be disassembled or opened. The only serviceable items are the sprocket and the support.

GC0157479Courtesy of CHRYSLER GROUP, LLC
  1. Disconnect and isolate the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), disconnect the IBS connector first before disconnecting the negative battery cable.
  2. Remove the engine cover. Refer to the appropriate service information article (1).
  3. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
  4. Remove the belly pan. Refer to BELLY PAN, REMOVAL .
  5. Remove the tire and wheel assembly.
  6. Remove the right front wheelhouse splash shield. Refer to SHIELD, SPLASH, REAR WHEELHOUSE, REMOVAL .
  7. Drain cooling system. Refer to DRAINING .
  8. Remove the support and lower the vehicle.
    GC0147935Courtesy of CHRYSLER GROUP, LLC
  9. Disconnect the boost pressure wire harness connector (1).
    GC0147890Courtesy of CHRYSLER GROUP, LLC
  10. Disconnect the fuel quantity solenoid wire harness connector (2).
  11. Detach the wire harness retainer at upper timing cover and position aside the engine wire harness.
  12. Remove the upper timing cover. Refer to the appropriate service information article .
    GC0148119Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    Do not crimp or bend fuel lines. Capture all fluids that flow out of connections.

    NOTE:

    Fuel return manifold removed for clarity.

  13. Remove the fuel tube (2) between the fuel injection pump (3) and the fuel rail (1).
    GC0159461Courtesy of CHRYSLER GROUP, LLC
  14. Disconnect the fuel supply (2) line and return line (1) quick-connect fittings at fuel injection pump. Refer to FITTING, QUICK CONNECT  .
    GC0147915Courtesy of CHRYSLER GROUP, LLC
  15. Detach the fuel supply line from the retainer clip.
  16. Remove bolts (1) and the fuel injection pump guard (2).
    GC0148121Courtesy of CHRYSLER GROUP, LLC
  17. Disconnect the fuel injector return line at the fuel return manifold (1).
  18. Loosen the clamp and disconnect the fuel return hose (3) from the fuel injection pump.
  19. Remove bolts (2) and position aside the fuel return manifold (1).
    GC0148122Courtesy of CHRYSLER GROUP, LLC
  20. Remove the coolant manifold (1) at intake manifold.
    GC0147916Courtesy of CHRYSLER GROUP, LLC
  21. Rotate the crankshaft far enough to align the threaded holes in the pressure pump sprocket with the corresponding holes in the pressure pump support.
  22. Install and tighten the (special tool #20150, Remover/Installer, High Pressure Fuel Pump) (2) to secure the fuel injection pump sprocket.
  23. Remove the nut (1) securing the sprocket to the fuel injection pump shaft.
    GC0148123Courtesy of CHRYSLER GROUP, LLC
  24. Remove the three nuts (1) securing the fuel injection pump (2).
    GC0159953Courtesy of CHRYSLER GROUP, LLC
  25. Install the (special tool #10499, Remover, Pulley) (2) and the (special tool #20150, Remover/Installer, High Pressure Fuel Pump) bolts (1) onto fuel injection pump sprocket (3).
  26. Using the extractor, separate the fuel injection pump from sprocket (2) and remove the fuel injection pump.
  27. Remove the (special tool #20150, Remover/Installer, High Pressure Fuel Pump) bolts (3) and the Remover, Pump Pulley 10499 (1) from the fuel injection sprocket (2).
    GC0148120Courtesy of CHRYSLER GROUP, LLC
  28. If necessary, remove fasteners (2) and the fuel quantity solenoid (1).
scientia non olet · About LEMON Manuals