High-Pressure Fuel Pump: Removal

All Vehicles 

1. With the vehicle in NEUTRAL, position it on a hoist. Refer to: Jacking and Lifting .
2. Release the fuel system pressure. Refer to: Fuel System Pressure Release .
3. Disconnect the battery negative cable. Refer to: Battery Disconnect and Connect .
4. Remove the cowl panel. Refer to: Cowl Panel .
5. Remove the intake manifold. Refer to: INTAKE MANIFOLD
6. With hybrid engine only, remove the wire harness retaining nut and move the harness out of the way.

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7. Detach the coolant hose retainer.

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8. NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.

   Remove the fuel injection pump noise insulator.

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9. NOTE: To release the fuel pressure in the high-pressure fuel tube, wrap the high-pressure fuel tube flare nuts with a shop towel to absorb any residual fuel pressure during the loosening of the high-pressure fuel tube flare nuts.

   Remove the high-pressure fuel tube bracket nuts. Disconnect the high-pressure fuel tube flare nuts, then remove and discard the high-pressure fuel tube.

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10. Remove the high-pressure fuel pump shield nuts.

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    U625 Explorer 

11. Remove the high-pressure fuel pump shield bolt, then remove the shield.

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12. Disconnect the high-pressure fuel pump fuel feed spring lock coupling.

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    U611 Aviator 

13. Remove the high-pressure fuel pump shield bolt, then position the shield up and out of the way.

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14. Disconnect the high-pressure fuel pump fuel feed spring lock coupling, then remove the high-pressure fuel pump shield.

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    All Vehicles 

15. Alternately loosen the high-pressure fuel pump nuts one complete revolution at a time and remove, then remove the high-pressure fuel pump.

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16. Remove and discard the high-pressure fuel pump O-ring seal.

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17. Remove the high-pressure fuel pump roller tappet.

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18. Inspect the high-pressure fuel pump roller tappet. If any flat spots or scoring are found, especially in the indicated areas, then inspect the high-pressure fuel pump and the high-pressure fuel pump roller tappet drive lobe. Install new components as needed.

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19. If needed, remove the high-pressure fuel pump mounting studs.

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