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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 >> 2.2L Diesel

2.2L 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.

  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. .
  3. Remove the air cleaner body. Refer to BODY, AIR CLEANER, REMOVAL .
  4. Remove the engine timing cover. Refer to the appropriate service information article .
    GC0176945Courtesy of CHRYSLER GROUP, LLC
  5. Remove the bolt (2) and the eyelet bracket (1).
  6. Remove the bolt (3) securing the coolant tube.
    GC0177029Courtesy of CHRYSLER GROUP, LLC
  7. Disconnect the fuel return line (1) from fuel manifold.
    GC0175370Courtesy of CHRYSLER GROUP, LLC
  8. Disconnect the fuel quantity solenoid wire harness connector (1).
  9. Disconnect the fuel supply (2) line quick-connect fitting from the fuel injection pump.
  10. Undo the clamp and remove fuel return line (3) from the fuel injection pump.
    GC0177070Courtesy of CHRYSLER GROUP, LLC
  11. Remove the bolts (1) and position aside the fuel return manifold (2).
    GC0169944Courtesy of CHRYSLER GROUP, LLC
  12. Remove the fuel injection pump insulator (1).
    GC0177005Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

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

  13. Unscrew the union nuts (1, 3) and remove the fuel tube (2).
    GC0147915Courtesy of CHRYSLER GROUP, LLC
  14. Remove the bolts (1) and the fuel injection pump guard (2).
    GC0177079Courtesy of CHRYSLER GROUP, LLC
  15. Detach the wire harness retainer (1) securing the wire harness (2) under the right side Power Distribution Center (PDC) and position aside the wire harness.
    GC0177037Courtesy of CHRYSLER GROUP, LLC
  16. Remove the nuts (1) and position aside the right side PDC with mounting bracket mounting bracket.
    GC0176976Courtesy of CHRYSLER GROUP, LLC
  17. Install the (special tool #2029900090, Remover, Pressure Pump Pulley) locking ring (1) and screw the pins (2) into the pressure pump sprocket and securely tighten.
    GC0176944Courtesy of CHRYSLER GROUP, LLC
  18. Install the (special tool #2029900090, Remover, Pressure Pump Pulley) tool (2) on the previously mounted pins and securely tighten the nuts (3).
  19. Install the bolts (1) securing the (special tool #2029900090, Remover, Pressure Pump Pulley) plate (2) and securely tighten.
    GC0176889Courtesy of CHRYSLER GROUP, LLC
  20. Using a shallow 24 mm socket(1), remove the nut securing the sprocket to the fuel injection pump shaft.
    GC0175367Courtesy of CHRYSLER GROUP, LLC
  21. Remove the three nuts (1) securing the fuel injection pump.
    GC0176941Courtesy of CHRYSLER GROUP, LLC
  22. Screw the pressure pin (1) into the plate and remove the fuel injection pump from the sprocket.
    GC0177046Courtesy of CHRYSLER GROUP, LLC
  23. Remove the fuel injection pump (1).
    GC0177006Courtesy of CHRYSLER GROUP, LLC
  24. If necessary remove fasteners (1) and the fuel quantity solenoid (2).
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