Removal Procedure
Fuel/gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.
Wear safety glasses in order to avoid eye damage.
- Relieve the low and high side fuel system pressure. Fuel Pressure Relief
- Remove the fuel pump insulator. Fuel Pump Insulator Replacement
- Disconnect the engine wiring harness electrical connector from the high pressure fuel pump.
- Remove the fuel feed pipe. Fuel Feed Pipe Replacement (At Tank) Fuel Feed Pipe Replacement (At Engine)
- Remove and DISCARD the fuel feed intermediate pipe. Fuel Feed Intermediate Pipe Replacement
- 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
Fuel Pump Bolt (1) - Remove and DISCARD[2x]
- Fuel Pump (2) - Remove
- 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.
- Valve Lifter Follower (3) - Remove
Remove and DISCARD the fuel pump O-ring (1).
- Remove and DISCARD the fuel pump gasket (2).
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.
Ensure that during removal of the fuel pump that the valve lifter follower does NOT fall apart.