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Home >> Ford >> 2022 >> Transit Connect Titanium, Gas/Ethanol >> Repair and Diagnosis >> External Pages >> Different car >> Section 684 (Fuel Charging And Controls - 3.0L Power Stroke Diesel) >> Removal And Installation >> Fuel Injection Pump >> Removal

Fuel Injection Pump: Removal

WARNING: This page is about a different car, the 2021 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.
  1. Release the fuel system pressure. Refer to: Fuel System Pressure Release .
  2. Remove the engine appearance cover.
    GFD555948Courtesy of FORD MOTOR COMPANY
  3. Remove the engine appearance cover bracket retainers, then remove the engine appearance cover bracket.
    GFD557285Courtesy of FORD MOTOR COMPANY
  4. Disconnect the battery negative cable. Refer to: Battery Disconnect and Connect .
  5. Disconnect the quick release couplings, detach the fuel tube retainers, then position out of the way. Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 3.0L Power Stroke Diesel).
    GFD557286Courtesy of FORD MOTOR COMPANY
  6. Disconnect the fuel supply tube assembly electrical connector, then detach the wire retainer.
    GFD557287Courtesy of FORD MOTOR COMPANY
    1. Disconnect the fuel supply tube assembly quick release couplings. Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 3.0L Power Stroke Diesel).
    2. Remove the bolt, then remove the fuel supply tube assembly.
    GFD557288Courtesy of FORD MOTOR COMPANY
  8. Disconnect the fuel tube assembly quick release coupling. Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 3.0L Power Stroke Diesel).
    GFD557289Courtesy of FORD MOTOR COMPANY
    1. If equipped, disconnect the quick release coupling. Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 3.0L Power Stroke Diesel).
    2. If equipped, detach the retainers, then position the vacuum tube out of the way.
    GFD557290Courtesy of FORD MOTOR COMPANY
  10. Remove the bolt, then remove the secondary fuel filter.
    GFD557291Courtesy of FORD MOTOR COMPANY
  11. Detach the wiring harness bracket from the rear engine lifting eye and from the transmission case, then position out of the way.
    GFD557292Courtesy of FORD MOTOR COMPANY
    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 (310-00 Fuel System - General Information - 3.0L Power Stroke Diesel).
    3. Detach the valve from the bracket.
    4. Detach the vacuum reservoir retainers, then remove the vacuum tube assembly.
    GFD557293Courtesy of FORD MOTOR COMPANY
  13. Detach the fuel injector fuel return line retainers, then remove the wiring harness bolt.
    GFD557294Courtesy of FORD MOTOR COMPANY
  14. Detach the wire harness retainers, then move out of the way.
    GFD557295Courtesy of FORD MOTOR COMPANY
  15. Remove the retainers, then remove the bracket.
    GFD557296Courtesy of FORD MOTOR COMPANY
  16. Remove the fuel tube bracket bolt, then remove the bracket.
    GFD557297Courtesy of FORD MOTOR COMPANY
  17. Detach the wire harness and the coolant hose retainers, then position out of the way.
    GFD557298Courtesy of FORD MOTOR COMPANY
  18. Remove the right insulator.
    GFD557299Courtesy of FORD MOTOR COMPANY
  19. Remove the left insulator.
    GFD557300Courtesy of FORD MOTOR COMPANY
  20. Remove the air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe .
  21. 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.

    GFD557301Courtesy of FORD MOTOR COMPANY
  22. 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.

    GFD557302Courtesy of FORD MOTOR COMPANY
  23. 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 (310-00 Fuel System - General Information - 3.0L Power Stroke Diesel).

    GFD557303Courtesy of FORD MOTOR COMPANY
  24. Disconnect the fuel injector electrical connectors, then detach the wiring harness retainers.
    GFD557304Courtesy of FORD MOTOR COMPANY
  25. 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.

    GFD557305Courtesy of FORD MOTOR COMPANY
    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.
    GFD557306Courtesy of FORD MOTOR COMPANY
  27. Disconnect the fuel injection pump electrical connector.
    GFD557307Courtesy of FORD MOTOR COMPANY
    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.
    GFD557308Courtesy of FORD MOTOR COMPANY
  29. Remove the rear end accessory drive belt. Refer to: Rear End Accessory Drive (READ) .
  30. 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.

    GFD557309Courtesy of FORD MOTOR COMPANY
  31. Remove the accessory drive cover stud bolts, then remove the cover.
    GFD557310Courtesy of FORD MOTOR COMPANY
  32. Remove the bolts, then remove the fuel injection pump bracket.
    GFD557311Courtesy of FORD MOTOR COMPANY
  33. 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.
    GFD557312Courtesy of FORD MOTOR COMPANY
  34. Using special tool, remove the fuel injection pump sprocket. Use Special Service Tool: 303-1678 Remover, Fuel Pump Pulley Holding Tool.
    GFD557313Courtesy of FORD MOTOR COMPANY
  35. Remove the bolts, then remove the fuel injection pump.
GFD557314Courtesy of FORD MOTOR COMPANY
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