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.
WARNING:
Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
NOTE:
Do not loosen any fittings or plugs on the fuel injection pump.
- 1.
Release the fuel system pressure. Refer to: Fuel System Pressure Release .
- 2.
Disconnect the battery. Refer to: Battery Disconnect and Connect .
- 3.
Remove the ignition coil-on-plugs. Refer to: Ignition Coil-On-Plug .
- 4.
Remove the air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe .
- 5.
- 1.
Disconnect the crankcase ventilation tube quick release coupling. Release the hose retainer, release the clamp and then remove the crankcase ventilation tube. Refer to: Quick Release Coupling .
- 2.
Remove the TC air inlet pipe nut, the ball stud and loosen the TC air inlet pipe clamp, then remove the TC inlet pipe.
- 1.
- 6.NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.
Remove the high-pressure fuel pump noise insulator.
- 7.
- Release the wiring harness retainers. Disconnect the FRP sensor electrical connector, the fuel injection pump electrical connector and the CMP electrical connector. Position the wiring harness aside.
- Remove the ignition coil-on-plug mounting bracket retaining nut. Loosen the captured remaining ignition coil-on-plug mounting bracket retainers and then remove the ignition coil-on-plug mounting bracket.
- 9.
- 1.
Disconnect the high-pressure fuel pump fuel supply tube. Refer to: Spring Lock Couplings .
- 2.
Remove the high-pressure fuel pump fuel supply tube studbolt.
- 3.
Disconnect the high-pressure fuel pump fuel supply tube flare nut. Remove and discard the high-pressure fuel pump fuel supply tube.
- 1.
- 10.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.
Disconnect the high-pressure fuel tube flare nuts. Remove and discard the high-pressure fuel tube.
- 11.NOTE: Alternately loosen the 2 fuel injection pump bolts one complete revolution at a time.
Remove the high-pressure fuel pump bolts and then remove the high-pressure fuel pump.
- 14.
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.