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
- Drain the cooling system. Cooling System Draining and Filling
- Air Inlet Grille Panel - Remove - Air Inlet Grille Panel Replacement
- Intake Manifold Cover - Remove - Intake Manifold Cover Replacement
- Air Cleaner Outlet Duct - Remove - Air Cleaner Outlet Duct Replacement
Remove the engine wiring harness clip (1) from the bracket.
- Remove the air cleaner resonator bracket bolt (2).
- Remove the air cleaner resonator bracket (3).
Remove the fuel feed front pipe bracket nut (1).
- Remove the fuel feed front pipe bracket (2) from the stud.
- Disconnect the fuel feed front pipe (3) from the fuel pump and reposition pipe and bracket as necessary. Fuel Feed Front Pipe Replacement
- 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
- Close all open connections with the EN-6015 plugs.
Use the BO-38185 pliers to disengage the heater water auxiliary pump hose clamp (1).
- Remove the heater water auxiliary pump hose (2) from the water outlet.
- Remove the heater water auxiliary pump hose (2) from the clip (3) and reposition the hose as necessary.
Disconnect the electrical connector (1).
Remove the engine wiring harness ground bolt (1).
- Remove the engine wiring harness clips (2) from the engine wiring harness bracket.
- Reposition the engine wiring harness (3) as necessary.
Remove the engine wiring harness bracket bolts (1).
- Remove the engine wiring harness bracket (2).
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).
Disconnect the engine wiring harness electrical connectors from any sensors, including at the fuel pump, as necessary, to provide enough space to work in the area around the fuel pump.
Ensure that during removal of the fuel pump that the valve lifter follower does NOT fall apart.