Removal Procedure
- Relieve the fuel system pressure. Fuel Pressure Relief
- Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection
- Remove the oil fill cap.
Intake Manifold Cover Bolt (1) - Remove [2x]
- Lift up on the front of the intake manifold cover (2).
Intake Manifold Cover (1) @ Upper Intake Manifold Bracket (2) - Remove
Intake Manifold Cover Bolt (1) - Remove
- Intake Manifold Cover Insulator (2) - Remove
Fuel Feed Pipe (1) @ Fuel Pump - Disconnect - Metal Collar Quick Connect Fitting Service
Electrical Connector (1) - Disconnect as necessary
Upper Intake Manifold Cover Nut (1) - Remove [2x]
- Radiator Surge Tank Inlet Hose Clip (2) @ Upper Intake Manifold Bracket (3) - Remove
Upper Intake Manifold Cover Nut (1) - Remove [2x]
- Upper Intake Manifold Bracket (2) - Remove
Fuel Pump Shield Bolt (1) - Remove [2x]
- Fuel Pump Shield Bolt (2) - Remove [2x]
- Fuel Injection Pump Bracket (3) - Remove
- WARNING:
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.
Fuel Pump Insulator (1) - Remove
Nut @ Fuel Feed Intermediate Pipe (1) - Loosen [2x]
Fuel Injection Fuel Feed Pipe Bracket Bolt (1) - Remove
- Fuel Feed Intermediate Pipe (2) - Remove and DISCARD
- Electrical Connector @ Fuel Pump - Disconnect
- CAUTION:
Alternately loosen the fuel pump bolts one turn at a time until the pump is fully disengaged from fuel pump lifter follower. Trying to remove the pump bolts without even side-to-side loosening may result in pump plunger damage
Fuel Pump Stud (1) - Remove [2x]
- Fuel Pump (2) - Remove
- Fuel Pump Seal (3) - Remove and DISCARD
- Valve Lifter Follower (4) - Remove
Refer to Diesel/Gasoline Vapors Warning .
Refer to Safety Glasses Warning .