Fuel Pump (G2110426): Removal
WARNING:
- Be prepared to collect escaping fuel.
- Residual pressure may still be present in the fuel system when disconnecting a fuel line. Make sure to cover the fuel line connection with a lint free cloth to capture any escaping fuel.
CAUTION:
- Extreme cleanliness must be exercised when handling these components. Make sure that all tools and the surrounding area is clean before commencing work.
- Before disconnecting any components, make sure the area is clean and free from foreign material. When disconnected all openings must be sealed.
NOTE:
- This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.
- This procedure contains illustrations showing certain components removed to provide extra clarity.
- Always follow the fuel system health and safety precautions when doing any repairs to the fuel system.
Refer to: PETROL AND PETROL-ETHANOL FUEL SYSTEMS HEALTH AND SAFETY PRECAUTIONS .
- Release the fuel system pressure.
Refer to: FUEL SYSTEM PRESSURE RELEASE .
- Disconnect the startup battery ground cable.
Refer to: 12V SYSTEM DISCONNECT .
- Clean all the fuel line unions and the surrounding area before working on the fuel system.
Refer to: FUEL INJECTION COMPONENT CLEANING .
- Remove the engine cover.
Refer to: ENGINE COVER - INGENIUM I4 2.0L PETROL .
Remove the Noise, Vibration and Harshness (NVH) material.
- Release the engine vent oil separator hose.
- Release the clamp.
- Release the hose clip.
- Remove the engine vent oil separator hose.
Disconnect the High Pressure (HP) fuel pump electrical connector.
- Disconnect the 11 engine wiring harness electrical connectors as shown.
- Remove the 2 ground bolts.
- Remove the 2 engine wiring harness bracket nuts.
- Reposition the engine management harness.
Release the HP fuel line from the HP fuel pump.
Release the Low Pressure (LP) fuel delivery line from the HP fuel pump.
Disconnect the LP fuel delivery line.
- Remove the 2 fuel line bracket bolts.
- Release the fuel pump to fuel rail line union.
- Remove the LP fuel delivery line.
- Remove the fuel pump to fuel rail line.
- Loosen the 2 HP fuel pump bolts half a turn at a time alternating between the 2 bolts.
- Discard the 2 bolts.
- Remove the HP fuel pump.
Remove and discard the HP fuel pump O-ring seal.
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NOTE: Note the orientation of the HP fuel pump tappet prior to removal.
- Remove the HP fuel pump tappet.
- Examine the HP fuel pump tappet. Replace if damaged or worn.