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.
Lift up on the front of the intake manifold cover (1).
Intake Manifold Cover (1) @ Upper Intake Manifold Bracket (2) - Remove
Radiator Surge Tank Inlet Hose Clip (1) @ Positive Crankcase Ventilation Hose - Remove
- Radiator Surge Tank Inlet Hose Clip (3) @ Fuel Pump Cover - Remove
- Radiator Surge Tank Inlet Hose Clip (2) @ Engine Wiring Harness - Remove
Radiator Surge Tank Inlet Hose Clip (1) @ Radiator Surge Tank Inlet Pipe Bracket - Remove
- Radiator Surge Tank Inlet Hose Clip (2) @ Radiator Surge Tank Inlet Pipe Bracket - Remove
- Radiator Surge Tank Outlet Pipe (3) - Reposition
Fuel Feed Pipe (1) @ Fuel Pump - Disconnect - Metal Collar Quick Connect Fitting Service
Reposition wiring harness as necessary.
- Fuel Pump Shield Bolt (1) - Remove [3x]
- Fuel Pump Cover (2) - Remove
Reposition wiring harness as necessary.
- Fuel Pump Insulator (1) - Remove
Fuel Injection Fuel Feed Pipe Bolt (1) - Remove
- Fuel Feed Intermediate Pipe (2) - Remove and DISCARD
Disconnect the fuel pump electrical connector.
- Fuel Pump Bolt (4) - Remove [2x]
- Fuel Pump (1) - Remove
- Fuel Pump Seal (3) - Remove and DISCARD
- Valve Lifter Follower (2) - Remove
Refer to Diesel/Gasoline Vapors Warning .
Refer to Safety Glasses 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.
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