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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 409 (Engine Controls - Removal & Installation - Diesel) >> Fuel Systems >> Fuel Injection Pump >> Removal

Fuel Injection Pump: Removal

WARNING: This page is about a different car, the 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Cover the air intake pipe end with duct tape to prevent the infiltration of dirt. Cap all of the open fuel connections with suitable plastic plugs in order to prevent infiltration of dirt.
NOTE: Remove only the air conditioning/power steering bracket. Do not discharge the A/C or remove the A/C and power steering lines. The Fan Clutch Remover and Installer Set (J-46406, set contains Wrench J-41240 and Holder J41240-5A) is required to remove and install fan blade assembly. See Figure.
  1. Disconnect negative battery cables. Remove the air intake duct between the air cleaner and the turbocharger inlet housing. Drain the coolant. Remove the upper fan shroud. See FAN SHROUD (UPPER)  under MISCELLANEOUS.
  2. Remove the fan blade assembly by using the fan clutch remover and installer set and turning the fan hub nut from the water pump in a counterclockwise rotation. See Figure. Remove drive belt by installing a 3/8 inch breaker bar into the tensioner opening and rotate the tensioner counterclockwise. See Figure. Remove the drive belt from the drive pulleys. Slowly release the tension on the tensioner arm.
  3. Remove the bolt holding the positive battery cable junction box and bracket and move out of the way. Remove the A/C compressor. See appropriate article in AIR CONDITIONING & HEATING. Remove the power steering pump. See appropriate Power Recirculating Ball article in STEERING. Position the A/C compressor and power steering pump aside. Remove the engine oil fill tube bolts. Remove the oil fill tube. Remove and discard the oil fill tube "O" ring seal.
  4. Remove the air conditioning/power steering bracket. Disconnect the alternator electrical connector. Remove the alternator bolt. Remove the alternator. Slide the boot down revealing the terminal stud. Remove alternator nut cable from the stud terminal and remove cable. Remove the thermostat housing bracket, wiring and fuel test port, and two nuts. Remove the Positive Crankcase Ventilation (PCV) catch tank from the PCV bracket and bolt below holding lower line, and reposition.
  5. Remove the right idler pulley bolt and pulley. Remove the left idler pulley bolt and pulley. Remove the drive belt tensioner bolt and tensioner. Remove the fuel bleed valve nuts and valve. Reposition the oil separator hose clamp at the side of the alternator bracket.
  6. Remove the oil separator hose from the pipe. If equipped, remove the vacuum line from the exhaust gas recirculation (EGR) valve vacuum pump. If equipped, remove the EGR vacuum pump bolts. Reposition the vacuum pump. Reposition the oil separator hose clamp at the bottom of the alternator bracket. Remove the oil separator hose from the bracket. Remove the generator bracket bolts. Remove the alternator bracket.
  7. Remove the turbo cooling hose return line clamp and hose. Remove the upper radiator hose at the outlet pipe. Remove the bracket and support the bracket at the valve cover, and swing out of the way. Remove bolt holding wiring support bracket at thermostat housing.
  8. Move the main wiring harness by disconnecting the fuel pressure regulator connector on the fuel injection pump and the fuel injection control module connectors. Flip the wire harness and harness tray towards the back and set aside. Disconnect the heater pipe bolt and temperature sensor wire from the thermostat housing.
  9. Remove the air intake pipe. See AIR INTAKE PIPE  under AIR INDUCTION SYSTEMS. Remove the thermostat crossover assembly. See THERMOSTAT HOUSING COVER under REMOVAL & INSTALLATION in 6.6L V-8 DIESEL article in ENGINES.
  10. Remove the turbo water feed line/hoses as necessary. See Fig 1. Disconnect all high pressure fuel lines and remove supply pipe and hose at the fuel injection pump and junction block. See QUICK CONNECT FITTINGS (METAL COLLAR) .
  11. Remove the supply hose from the fuel injection pump. Remove the fuel return hose from fuel injection pump. Remove the high pressure line from the injection pump to the junction block. Remove fuel injection pump mounting bolts from the front of the engine front cover.
  12. Remove fuel injection pump from the block using two screwdrivers to work the pump from the block towards rear of engine keeping the pump straight. Be careful not to damage any mating surfaces. Remove fuel injection pump. See Fig 2.
Fig 1: Removing/Installing Turbo Water Feed Line
G00232250Courtesy of GENERAL MOTORS CORP.
Fig 2: Removing Fuel Injection Pump
G00058508Courtesy of GENERAL MOTORS CORP.
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