Removal Procedure
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.
Refer to Diesel/Gasoline Vapors Warning .
Refer to Safety Goggles and Fuel Warning .
- Relieve the fuel system pressure. Fuel Pressure Relief
- Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection (without KL9) , or Battery Negative Cable Disconnection and Connection (with KL9)
- Intake Manifold - Remove - Intake Manifold Replacement
Disconnect the fuel feed front pipe (1) from the fuel pump. Fuel Feed Front Pipe Replacement
Disconnect the engine wiring harness electrical connectors (1) as necessary, including the electrical connector at the fuel pump.
- Remove the engine wiring harness bracket bolts (2) and reposition the engine wiring harness bracket (3).
- NOTE:
High pressure fuel feed pipes are one time use only. ALWAYS install a NEW high pressure fuel feed pipe if the pipe is removed OR the fittings are loosened.
Remove and DISCARD the fuel feed intermediate pipe (1). Fuel Feed Intermediate Pipe Replacement
Remove the fuel pump insulator (1).
- CAUTION:
Alternately loosen the fuel pump bolts one turn at a time until the pump is fully disengaged from fuel pump lifter follower. Trying to remove the pump bolts without even side-to-side loosening may result in pump plunger damage
Remove and DISCARD the fuel pump bolts (1).
- Remove the fuel pump (2).
- The valve lifter follower MAY remain in the cylinder head bore after removing the fuel pump.
- If the valve lifter follower does NOT pull out of the cylinder head bore with the fuel pump, then remove it afterwards.
- Remove the valve lifter follower (3).
Remove and DISCARD the fuel pump housing seal (1).
It is NOT necessary to remove the evaporative emission canister purge solenoid valve or the throttle body from the intake manifold.
Ensure that during removal of the fuel pump that the valve lifter follower does NOT fall apart.