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Home >> Chevrolet >> 2016 >> Volt Premier >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Engine Controls And Fuel - 1.5L (L3A) - Repair Instructions >> Repair Instructions >> Fuel Injection Pump Replacement >> Removal Procedure

Removal Procedure

WARNING:

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.

  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief 
  2. Disconnect Battery Negative Cable. Refer to Battery Negative Cable Disconnection and Connection
  3. Drain the coolant. Refer to Cooling System Draining and Filling
  4. Remove Air Inlet Grille Panel. Refer to Air Inlet Grille Panel Replacement
  5. Remove Intake Manifold Cover. Refer to Intake Manifold Cover Replacement
  6. Remove Air Cleaner Outlet Duct. Refer to Air Cleaner Outlet Duct Replacement 
    7. Fig 1: Air Cleaner Resonator Bracket, Bolt And Wiring Harness Clip
    GM4091051Courtesy of GENERAL MOTORS COMPANY
  7. Unclip Wiring Harness Clip (3)
  8. Remove the air cleaner resonator bracket bolt (1).
  9. Remove the air cleaner resonator bracket (2).
    10. Fig 2: Fuel Feed Intermediate Pipe, Bolt And Nuts
    GM4091049Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Lay a lint-free cloth under the fuel feed intermediate pipe.

  10. Remove Fuel Feed Intermediate Pipe Bolt (1)
  11. Loosen Nuts (2, 5) (Qty: 2)
  12. Remove and DISCARD Fuel Feed Intermediate Pipe (6)
    13. Fig 3: Fuel Feed Front Pipe And Fuel Injection Pump
    GM4091024Courtesy of GENERAL MOTORS COMPANY
  13. Disconnect Fuel Feed Front Pipe (2) @ Fuel Injection Pump (1)
  14. Close all open connections with the EN-6015  plugs.
  15. Remove Fuel Feed Front Pipe (2)
    16. Fig 4: Engine Wiring Harness And Bracket
    GM4297788Courtesy of GENERAL MOTORS COMPANY
  16. Unclip Engine Wiring Harness (1) @ Engine Wiring Harness Bracket (2)
    17. Fig 5: Heater Outlet Hose And Clamp
    GM4091334Courtesy of GENERAL MOTORS COMPANY
  17. Loosen Heater Outlet Hose Clamp (2) using BO-38185  Pliers.
  18. Disconnect Heater Outlet Hose (1)
    19. Fig 6: Engine Wiring Harness Bracket, Bolts, Ground Cable And Electrical Connector
    GM4091309Courtesy of GENERAL MOTORS COMPANY
  19. Remove Bolt (4)
  20. Remove Ground Cable (5) @ Cylinder Head
  21. Remove Engine Wiring Harness Bracket Bolt (3) (Qty: 2) @ Engine Wiring Harness Bracket
  22. Disconnect the electrical connector (2).
  23. Remove Engine Wiring Harness Bracket (1)
    24. Fig 7: Fuel Injection Pump, Bolts, Gasket, Electrical Connector And Valve Lifter Follower
    GM4091372Courtesy of GENERAL MOTORS COMPANY
    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

  24. Loosen the 2 fuel injection pump bolts (4, 6) alternating in steps of 1/2 turn.
  25. Remove Fuel Injection Pump Bolt (Qty: 2)
  26. Disconnect the electrical connector (5).
    27. NOTE:

    Take care that during removal of the fuel injection pump the valve lifter follower (1) does not fall apart.

  27. Remove Fuel Injection Pump (3)
  28. Remove Valve Lifter Follower (1)
  29. Remove and DISCARD Fuel Injection Pump Gasket (2)
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