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Home >> Chevrolet >> 2017 >> 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.

WARNING:

Refer to Diesel/Gasoline Vapors Warning .

WARNING:

Refer to Safety Goggles and Fuel Warning .

  1. Relieve the fuel system pressure. Fuel Pressure Relief 
  2. Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection
  3. Drain the cooling system. Cooling System Draining and Filling
  4. Remove Air Inlet Grille Panel Air Inlet Grille Panel Replacement
  5. Remove Intake Manifold Cover Intake Manifold Cover Replacement
  6. Remove Air Cleaner Outlet Duct Air Cleaner Outlet Duct Replacement 
    7. Fig 1: Air Cleaner Resonator Bracket And Bolt
    GM4864718Courtesy of GENERAL MOTORS COMPANY
  7. Remove the engine wiring harness clip (1) from the bracket.
  8. Remove the air cleaner resonator bracket bolt (2).
  9. Remove the air cleaner resonator bracket (3).
    10. Fig 2: Fuel Feed Front Pipe Bracket And Nut
    GM4864719Courtesy of GENERAL MOTORS COMPANY
  10. Remove the fuel feed front pipe bracket nut (1).
  11. Remove the fuel feed front pipe bracket (2) from the stud.
  12. Disconnect the fuel feed front pipe (3) from the fuel pump and reposition pipe and bracket as necessary. Fuel Feed Front Pipe Replacement 
    13. Fig 3: Fuel Feed Intermediate Pipe
    GM4864720Courtesy of GENERAL MOTORS COMPANY
    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.

  13. Remove and DISCARD the fuel feed intermediate pipe. Fuel Feed Intermediate Pipe Replacement 
  14. Close all open connections with the EN-6015  plugs.
    15. Fig 4: Heater Water Auxiliary Pump Hose And Clip
    GM4864721Courtesy of GENERAL MOTORS COMPANY
  15. Use the BO-38185  pliers to disengage the heater water auxiliary pump hose clamp (1).
  16. Remove the heater water auxiliary pump hose (2) from the water outlet.
  17. Remove the heater water auxiliary pump hose (2) from the clip (3) and reposition the hose as necessary.
    18. Fig 5: Electrical Connector
    GM4864722Courtesy of GENERAL MOTORS COMPANY
  18. Disconnect the electrical connector (1).
    19. Fig 6: Engine Wiring Harness Ground Bolt And Harness Clips
    GM4864726Courtesy of GENERAL MOTORS COMPANY
  19. Remove the engine wiring harness ground bolt (1).
  20. Remove the engine wiring harness clips (2) from the engine wiring harness bracket.
    21. NOTE:

    Disconnect any engine wiring harness electrical connectors from sensors, including the fuel pump, as necessary, to provide enough space to work in the area around the fuel pump.

  21. Reposition the engine wiring harness (3) as necessary.
    22. Fig 7: Engine Wiring Harness Bracketand Bolts
    GM4864727Courtesy of GENERAL MOTORS COMPANY
  22. Remove the engine wiring harness bracket bolts (1).
  23. Remove the engine wiring harness bracket (2).
    24. Fig 8: Fuel Pump Insulator
    GM4864728Courtesy of GENERAL MOTORS COMPANY
  24. Remove the fuel pump insulator (1).
    25. Fig 9: Fuel Pump Bolts
    GM4864729Courtesy 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

  25. Remove and DISCARD the fuel pump bolts (1).
    26. NOTE:

    Ensure that during removal of the fuel pump that the valve lifter follower does NOT fall apart.

  26. Remove the fuel pump (2).
    27. NOTE:
    • 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.
  27. Remove the valve lifter follower (3).
    28. Fig 10: Fuel Pump Housing Seal
    GM4864734Courtesy of GENERAL MOTORS COMPANY
  28. Remove and DISCARD the fuel pump housing seal (1).
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