High Pressure Fuel Pump

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 could be as high as 410 bar (5, 946 psi). Use extreme caution when inspecting for high-pressure fuel leaks. Inspect for high-pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system. Fuel under this amount of pressure can penetrate skin causing serious or fatal injury.

REMOVAL

Remove the high pressure fuel line. Refer to LINES AND TUBES, FUEL, REMOVAL AND INSTALLATION .

Courtesy of CHRYSLER GROUP, LLC

1 - Fuel Line Quick-Connect Fitting

2 - Fuel Line Retainer

3 - High Pressure Fuel Pump NVH Cover

Remove the fuel supply line quick-connect fitting.

Remove the fuel pump Noise Vibration Harshness (NVH) cover.

Courtesy of CHRYSLER GROUP, LLC

1 - High Pressure Pump

2 - High Pressure Pump Bore Cover

3 - High Pressure Pump Bore Cover Bolts

4 - High Pressure Pump Bolts

Remove the bolts that secure the high pressure pump to the engine block and remove it from the vehicle.
NOTE:
To avoid side loading damage to the pump, remove the fuel injection pump bolts at the same time, or in alternating one half turn increments and remove the fuel injection pump complete with roller tappet.
Using a suitable tool remove the high pressure fuel pump tappet from the engine block.

CAUTION:

To avoid side loading damage to the pump during assembly, the nuts need to be run down at the same time, or in alternating one half turn increments. Do not torque to specification until the mounting flange is in full contact with the cylinder head.

INSTALLATION

Follow the removal procedure in reverse for general reassembly of the components on the vehicle. The steps listed below are calling out specific procedures that should be followed during installation.

Rotate engine cylinder No. 1 to 30° past Top Dead Center (TDC) for the rear pump.
Apply a thin coat of clean motor oil to the high pressure pump O-ring.
Using an offset torque adapter can affect the actual torque applied to the fittings depending on the length and angle of the adapter relative to the torque wrench.
Inspect the high pressure fuel pump tappet, lubricate prior to installation.
To avoid side loading damage of pump during assembly, the bolts must draw fuel pump down against spring in alternating one half turn increments until target torque is reached. Do not torque to specification until the mounting flange is in contact & flush with the cylinder block.