High-Pressure Fuel Pump: Removal
WARNING: This page is about a different variant/trim than selected.
NOTE:
The turbocharger compressor vanes can be damaged by even the smallest particles. When removing any turbocharger or engine air intake system component, ensure that no debris enters the system. Failure to do so may result in damage to the turbocharger.
NOTE:
Special attention needs to be given to the sealing ports for the oil feed, the oil drain, and the coolant lines, on turbocharged engines. The sealing ports must be totally clean and free from O-ring residue, have no damage to the sealing surface and the lines to ensure that there are no leaks or repeat repairs.
- Release the fuel system pressure. Refer to: Fuel System Pressure Release .
- Disconnect the battery. Refer to: Battery Disconnect and Connect .
- Remove the engine appearance cover.
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- Remove the air cleaner outlet pipe retainer.
- Disconnect the quick release coupling and detach the hose retainers. Refer to: Quick Release Coupling .
- Loosen the clamps and remove the air cleaner outlet pipe.
- Disconnect the electrical connectors and detach the wire harness retainers.
- Disconnect the high-pressure fuel pump fuel feed tube quick release coupling. Refer to: Quick Release Coupling
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NOTE: To release the fuel pressure in the high-pressure fuel tube, wrap the high-pressure fuel pump flare nut with a shop towel to absorb any residual fuel pressure during the loosening of high-pressure fuel pump flare nut.
Remove the high-pressure fuel tube retaining nut and bolt. Loosen the high-pressure fuel tube flare nuts, disconnect, remove and discard the high-pressure fuel tube.
- Remove the high-pressure fuel pump bracket bolts and the fuel injection fuel pump bracket.
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NOTE: Alternately loosen the high-pressure fuel pump bolts one complete revolution at a time.
Remove and discard the high-pressure fuel pump bolts, then remove the high-pressure fuel pump.
- Remove and discard the high-pressure fuel pump O-ring seal.
- Remove the high-pressure fuel pump drive tappet.
- Inspect the high-pressure fuel pump tappet. If any flat spots or scoring are found, especially in the indicated areas, then inspect the high-pressure fuel pump and the high-pressure fuel pump tappet drive lobe. Install new components as needed.