Fuel Injection Pump: Removal

WARNING: This page is about a different car, the 2020 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: 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.

NOTE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components.

Release the fuel system pressure. Refer to: Fuel System Pressure Release .
Remove the engine appearance cover.

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Remove the engine appearance cover bracket retainers, then remove the engine appearance cover bracket.

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Disconnect the battery negative cable. Refer to: Battery Disconnect and Connect .
Disconnect the quick release couplings, detach the fuel tube retainers, then position out of the way. Refer to Quick Release Coupling .

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Disconnect the fuel supply tube assembly electrical connector, then detach the wire retainer.

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1. Disconnect the fuel supply tube assembly quick release couplings. Refer to Quick Release Coupling
2. Remove the bolt, then remove the fuel supply tube assembly.
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Disconnect the fuel tube assembly quick release coupling. Refer to Quick Release Coupling

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1. If equipped, disconnect the quick release coupling. Refer to Quick Release Coupling
2. If equipped, detach the retainers, then position the vacuum tube out of the way.
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Remove the bolt, then remove the secondary fuel filter.

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Detach the wiring harness bracket from the rear engine lifting eye and from the transmission case, then position out of the way.

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1. Disconnect the vacuum hose from the EGR, then detach the vacuum tube retainers.
2. Disconnect the electrical connector, then disconnect the quick release coupling. Refer to Quick Release Coupling :
3. Detach the valve from the bracket.
4. Detach the vacuum reservoir retainers, then remove the vacuum tube assembly.
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Detach the fuel injector fuel return line retainers, then remove the wiring harness bolt.

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Detach the wire harness retainers, then move out of the way.

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Remove the retainers, then remove the bracket.

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Remove the fuel tube bracket bolt, then remove the bracket.

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Detach the wire harness and the coolant hose retainers, then position out of the way.

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Remove the right insulator.

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Remove the left insulator.

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Remove the air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe .
NOTE: The fuel rail supply tube cannot be reused.
1. Remove the fuel rail supply tube bolt.
2. Loosen the fuel rail supply tube fittings, then remove and discard the fuel rail supply tube.
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NOTE: The fuel rail supply tube cannot be reused.

Loosen the fuel rail supply tube fittings, then remove and discard the fuel rail supply tube.

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NOTE: The fuel return tube cannot be reused.

Disconnect the quick release couplings, detach the fitting from the stud, detach the fuel return tube retainers, then remove and discard the fuel return tube. Refer to Quick Release Coupling .

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Disconnect the fuel injector electrical connectors, then detach the wiring harness retainers.

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NOTE: The use of long needle nose pliers or another commercially available tool may aid in the releasing of the center fuel injector fuel return line fitting lock.

Pull up on the center of the fuel injector fuel return line fittings to release the locks.

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1. NOTE: The use of long needle nose pliers or another commercially available tool may aid in the disconnecting of the fuel injector fuel return line fitting.
  
  Pull up on the fuel injector fuel return line fittings to disconnect the fuel injector fuel return line fittings from the fuel injectors.
2. Detach the fuel injector fuel return line retainers, then remove the fuel injector fuel return line.
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Disconnect the fuel injection pump electrical connector.

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1. NOTE: The fuel rail balance tube cannot be reused.
  
  Remove the fuel rail balance tube bolts, then remove the clamp.
2. Loosen and disconnect the fuel rail balance tube fittings at the fuel rails, then remove and discard the fuel rail balance tube.
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Remove the rear end accessory drive belt. Refer to: Rear End Accessory Drive (READ) .
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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Remove the accessory drive cover stud bolts, then remove the cover.

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Remove the bolts, then remove the fuel injection pump bracket.

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Using special tool, hold the fuel injection pump sprocket, then remove the fuel injection pump sprocket nut. Use Special Service Tool: 303-1678 Remover, Fuel Pump Pulley Holding Tool.

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Using special tool, remove the fuel injection pump sprocket. Use Special Service Tool: 303-1678 Remover, Fuel Pump Pulley Holding Tool.

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Remove the bolts, then remove the fuel injection pump.

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