Pump, Fuel Injection: Removal

CAUTION:

Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only.

WARNING:

High-pressure lines deliver diesel fuel under extreme pressure from the injection pump to the fuel injectors. Use extreme caution when inspecting for high-pressure fuel leaks. Fuel under this amount of pressure can penetrate skin causing personal injury or death. Inspect for high-pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system.

Disconnect and isolate the negative battery cable.
Remove the engine cover.

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Remove the plugs (1) from the cylinder head cover.

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Install the (special tool #99360614, Pins, Camshaft Locking) (1).

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Unscrew the fuel tube union nut (2) from the fuel rail.
Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .

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Remove the nuts (1) and position aside the coolant tube (2).

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Remove the banjo bolt (1) from the brake booster vacuum tube.

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Remove the bolts (1) and the brake booster vacuum tube (2).

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Disconnect the fuel quantity solenoid wire harness connector (1).

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Disconnect the oil pressure sensor wire harness connector (1).

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Remove the bolt (1) securing the fuel tube to intake manifold.
Unscrew the union nut (2) and remove the fuel tube (3).

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Loosen the clamp and remove the fuel supply line (1) from the fuel injection pump.
Disconnect the fuel return line (2) quick connect fitting from the fuel injection pump. Refer to FITTING, QUICK CONNECT .

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Remove the inner bolt (1) from the fuel injection pump (2).

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Remove the bolts (2) securing the high pressure pump.

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Slide the fuel injection pump (2) rearward to remove and use care not to drop the fuel injection sprocket (1).