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Home >> Alfa Romeo >> 2019 >> Giulia Base, AWD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> 2.0L - Fuel System >> Fuel Delivery >> Pump, Fuel Injection >> Removal And Installation

Removal And Installation

NOTE:

High-pressure fuel lines deliver fuel under extreme pressure from the injection pump to the injectors. This maybe as high as 207 bar (3, 002 psi). Use extreme caution when inspecting for high-pressure fuel leaks. Inspect 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 

  1. Perform the fuel system pressure release. Refer to FUEL SYSTEM PRESSURE RELEASE  .
  2. Disconnect and isolate the negative battery cable.
  3. Remove the intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL AND INSTALLATION .
  4. Remove the catalytic convertor. Refer to CONVERTER, CATALYTIC, REMOVAL AND INSTALLATION .
  5. Remove the coolant supply to turbocharger pipe. Refer to HOSE, COOLANT, REMOVAL AND INSTALLATION .
  6. Remove the high pressure fuel line. Refer to LINES, FUEL, REMOVAL AND INSTALLATION .
    GC0183296Courtesy of CHRYSLER GROUP, LLC
  7. Rotate the crankshaft clockwise (as viewed from the front) and position the damper notch (1) 90° from the timing cover mark (2) to place the camshaft between pump cam lobes (zero lift). This will relieve pressure from the pump roller tappet.
    GC0194513Courtesy of CHRYSLER GROUP, LLC
  8. Disconnect the wire harness connector (1) from the high pressure pump.
    GC0193967Courtesy of CHRYSLER GROUP, LLC
  9. Disconnect the front fuel supply pipe quick coupling to the high pressure pump.
    GC0194202Courtesy of CHRYSLER GROUP, LLC
  10. Remove the sound protection cover (1).
    GC0193208Courtesy of CHRYSLER GROUP, LLC
  11. Remove the nuts (1a) and remove the high pressure pump (1b) complete with roller tappet (1c).

INSTALLATION 

  1. Lubricate the roller tappet and its housing with engine oil, the O-ring on the high pressure pump and the roller tappet bore in the cylinder head.
  2. To install the high pressure pump, turn the engine crankshaft to position the cam of the high pressure pump to the home position (zero lift).
    GC0193375Courtesy of CHRYSLER GROUP, LLC
    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.

  3. Install the high pressure pump (1a) complete with roller tappet (1b) onto the cylinder head and tighten the nuts (1c) to the proper specification. Refer to FUEL SYSTEM PRESSURE RELEASE  .
    NOTE:

    The side anti-rotation roller "a" must be inserted in the groove on the cylinder head.

  4. Install the sound protection cover onto the high pressure pump.
  5. Connect the front fuel supply pipe quick coupling to the high pressure pump.
  6. Connect the wire harness connector to the high pressure pump.
  7. Install the high pressure fuel line. Refer to LINES, FUEL, REMOVAL AND INSTALLATION .
  8. Install the coolant supply to turbocharger pipe. Refer to HOSE, COOLANT, REMOVAL AND INSTALLATION .
  9. Install the catalytic convertor. Refer to CONVERTER, CATALYTIC, REMOVAL AND INSTALLATION .
  10. Install the intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL AND INSTALLATION .
  11. Connect the negative battery cable.
  12. Check the high pressure fuel system for leaks. Refer to FUEL SYSTEM PRESSURE RELEASE  .
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