Pump, Fuel Injection, High Pressure: Removal
Observe the following precautions when working on fuel systems: No sparks, open flames or smoking. Avoid inhaling and swallowing fuel. Avoid eye and skin contact with fuel. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing. Failure to observe these precautions may result in fire, explosion, property damage, and serious or fatal injury.
High-pressure fuel lines deliver fuel under extreme pressure from the injection pump to the injectors. This could be as high as 207 bar (3, 002 psi). Use extreme caution when inspecting for high-pressure fuel leaks. Inspect for high-pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system. Fuel under this amount of pressure can penetrate skin causing serious or fatal injury.
- Perform the fuel system pressure release procedure. Refer to FUEL SYSTEM PRESSURE RELEASE .
- Disconnect and isolate the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), disconnect the IBS connector first before disconnecting the negative battery cable.
- Remove the catalytic converter. Refer to CONVERTER, CATALYTIC, REMOVAL .
- Remove the Powertrain Control Module (PCM). Refer to MODULE, POWERTRAIN CONTROL (PCM), REMOVAL
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- Rotate the crankshaft clockwise (as viewed from the front) and position the damper notch (1) 90 degrees (2) from the timing cover mark (3) to place the camshaft between pump cam lobes (zero lift). This will relieve pressure from the pump roller tappet.
- Remove the bolt (1) for the coolant tube and slightly lower the tube.
- Disconnect the wire harness connector (1) from the fuel injection pump.
- Remove the high pressure fuel line (2) and discard.
- Disconnect the front fuel supply pipe (3) from the fuel injection pump.
- Remove the bolts (2) from the coolant tube and reposition the tube.
- Remove the sound protection cover (2) from the fuel injection pump.
- To avoid side loading damage to the pump, remove the nuts (1) at the same time, or in alternating one half turn increments and remove the fuel injection pump complete with roller tappet.