High-Pressure Fuel Pump: Removal
WARNING:
Do not work on the fuel system until the pressure has been released and the engine has cooled. Fuel in the high-pressure fuel system is hot and under very high pressure. High-pressure fuel may cause cuts and contact with hot fuel may cause burns. Failure to follow these instructions may result in serious personal injury.
WARNING:
Clean all fuel residue from the engine compartment. If not removed, fuel residue may ignite when the engine is returned to operation. Failure to follow this instruction may result in serious personal injury.
NOTE:
Do not loosen any fittings or plugs on the high-pressure fuel pump.
NOTE:
During the removal or installation of components, cap, tape or otherwise appropriately protect all openings and tubes/fittings to prevent the ingress of dirt or other contamination. Remove caps, tape and other protective materials prior to installation.
- Release the fuel system pressure. Refer to: Fuel System Pressure Release .
- Disconnect the battery. Refer to: BATTERY DISCONNECT AND CONNECT .
- Remove the intake manifold. Refer to: Intake Manifold .
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NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.
Remove the fuel injection pump noise insulator.
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- WARNING: Fuel may remain pressurized in some fuel lines after the Fuel System Pressure Release procedure. Wear safety gloves and a face shield when disconnecting pressure lines to avoid skin and eye contact. Failure to follow this instruction may result in serious personal injury.NOTE: Be prepared to collect escaping fluid.
Disconnect the fuel supply line from the high pressure fuel pump. Refer to: Quick Release Coupling .
- Disconnect the high pressure fuel pump electrical connector.
WARNING:
Fuel may remain pressurized in some fuel lines after the Fuel System Pressure Release procedure. Wear safety gloves and a face shield when disconnecting pressure lines to avoid skin and eye contact. Failure to follow this instruction may result in serious personal injury.
NOTE:
Be prepared to collect escaping fluid.
NOTE:
Always wrap the fuel line connection with a towel before disconnecting it.
- Detach the wiring harness retainer from the fuel tube bracket.
- Remove the high pressure fuel tube bracket bolts.
- Loosen the high pressure fuel tube flare nuts, remove and discard the high pressure fuel tube.
Loosen each bolt 1 turn at a time until all bolts are removed.
- Remove the high-pressure fuel pump bolts.
- Remove the high-pressure fuel pump.
Remove and discard the high-pressure fuel pump O-ring seal.
Remove the high-pressure fuel pump tappet.