Fuel Pump Replacement
Special Tools

EN-51365 High Pressure Fuel Pump Installation Alignment Gauge

Equivalent regional tools:Special Tools

Removal Procedure

Danger: 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: 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.

Warning: Wear safety glasses in order to avoid eye damage.

Caution: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution.

  1. Relieve the fuel system pressure.Fuel Pressure Relief
  2. Disconnect the battery negative cable.Battery Negative Cable Disconnection and Connection
  3. Intake Manifold»Remove—Intake Manifold Replacement

    4. 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.

  4. Fuel Feed Intermediate Pipe»Remove and DISCARD—Fuel Feed Intermediate Pipe Replacement

    5. Object ID: 4859666
  5. Disconnect the electrical connector (1).
  6. Remove the fuel pump insulator (2).

    7. Object ID: 4859660

    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

  7. Remove and DISCARD the fuel pump bolts (1).

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

  8. Remove the fuel pump (2).

    9. 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.

  9. Remove the valve lifter follower (3).

    10. Object ID: 4859663
  10. Remove and DISCARD the fuel pump housing seal (1).
Installation Procedure
  1. Before continuing, lubricate the cylinder head bore with clean engine oil. Adhesives, Fluids, Lubricants, and Sealers

    2. Object ID: 4860358
  2. Lubricate the valve lifter follower (1) with clean engine oil and install it into the cylinder head bore. Adhesives, Fluids, Lubricants, and Sealers

    3. Note:

    • The camshaft MUST be at the base circle position before the fuel pump is installed.
    • At the base circle position, the EN-51365 alignment gauge will sit flush with the cylinder head.

  3. Install the EN-51365 alignment gauge (2) and turn the crankshaft until the camshaft lobe is at the base circle position.
  4. Remove the EN-51365 alignment gauge (2) and valve lifter follower (1).

    5. Object ID: 4859663
  5. Lubricate the NEW fuel pump housing seal (1) with clean engine oil and install it on the fuel pump. Adhesives, Fluids, Lubricants, and Sealers

    6. Object ID: 4862457

    Caution: This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.

    Note:

    • ALWAYS make sure the fuel pump bolt retainers are present before installing the fuel pump bolts.
    • If ANY fuel pump bolt retainers are missing or NOT suitable for reuse, replace the retainers as necessary.

  6. Install the NEW fuel pump bolts (1) through the fuel pump bolt retainers (2).

    7. Object ID: 4862459
  7. Lubricate the valve lifter follower (1) again with clean engine oil, if necessary, and install it into the cylinder head bore. Adhesives, Fluids, Lubricants, and Sealers
  8. Install the fuel pump assembly (2) into the cylinder head and start the NEW fuel pump bolts (3) by hand.

    9. Caution: Refer to Fastener Caution.

    Caution: Alternately hand-tighten the fuel pump bolts one turn at a time until the pump is fully seated. Trying to draw down the pump without even side-to-side tightening may result in pump plunger damage.

  9. Tighten the NEW fuel pump bolts (3) to 25 N·m  (18 lb ft).

    10. Object ID: 4859666
  10. Install the fuel pump insulator (2).
  11. Connect the electrical connector (1).

    12. 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.

  12. Install the NEW fuel feed intermediate pipe. Fuel Feed Intermediate Pipe Replacement

    13. Note: The fuel feed front pipe will need to be disconnected after the fuel leak inspection to allow for installation of the intake manifold.

  13. Connect the fuel feed front pipe to the fuel pump. Fuel Feed Front Pipe Replacement
  14. Connect the battery negative cable.Battery Negative Cable Disconnection and Connection
  15. Inspect for leaks using the following procedure:
    1. Turn ON the ignition with the engine OFF for 2 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition with the engine OFF.
    4. Inspect for fuel leaks.
  16. Relieve the fuel system pressure.Fuel Pressure Relief
  17. Disconnect the battery negative cable.Battery Negative Cable Disconnection and Connection
  18. Disconnect the fuel feed front pipe from the fuel pump. Fuel Feed Front Pipe Replacement
  19. Intake Manifold»Install—Intake Manifold Replacement
  20. Connect the battery negative cable.Battery Negative Cable Disconnection and Connection
  21. Perform the fuel rail pressure relief valve learned values reset. Fuel Rail Pressure Relief Valve Learned Values Reset