Fuel Pump Replacement LLT
Special Tools
EN-48896 High Pressure Fuel Pump Installation Alignment Gage
Removal Procedure
- Relieve the low and high side fuel system pressure. Refer to
Fuel Pressure Relief
.
- Remove the high pressure fuel pump shield. Refer to
Fuel Pipe Shield Replacement
.
- Remove the intake manifold. Refer to
Intake Manifold Replacement
.
- Disconnect the engine wiring harness electrical connector from the high pressure fuel pump.
- Remove the low pressure feed pipe. Refer to
Fuel Feed Pipe Replacement
.
- Remove the high pressure pipe. Refer to
Fuel Feed Intermediate Pipe Replacement
. Discard this pipe.
- Remove and discard the high pressure fuel pump bolts (4).
- Remove the high pressure fuel pump (3).
- Remove and discard the high pressure fuel pump gasket (2).
- Remove and discard the high pressure fuel pump O-ring.
- Remove the high pressure fuel pump roller lifter.
Installation Procedure
Note: The camshaft must be in the base circle position before the high pressure fuel pump is installed.
- Use the
EN-48896 alignment gage
to ensure that the camshaft lobe is in the base circle position. At base circle the tool will be flush with the head.
- Lubricate the high pressure fuel pump cylinder head bore and roller lifter with camshaft prelube GM P/N 12345501 (Canadian P/N 992704) or equivalent.
- Install high pressure fuel pump roller lifter.
- Install a NEW high pressure fuel pump O-ring.
Note: The high pressure fuel pump gasket has a retaining feature to hold the pump retaining bolts in place.
- Position the NEW high pressure fuel pump gasket (2) and bolts (4) to the fuel pump.
- Install the high pressure fuel pump (3) to the cylinder head (1). Force will be required while hand tightening the bolts.
Caution: Refer to Fastener Caution in the Preface section.
- Tighten the high pressure fuel pump retaining bolts to
15 N·m (11 lb ft)
.
- Ensure the high pressure fuel pump and fuel rail fittings are clean prior to assembly.
- Install a NEW high pressure fuel pipe. Refer to
Fuel Feed Intermediate Pipe Replacement
.
- Install the fuel feed pipe to the high pressure fuel pump. Refer to
Fuel Feed Pipe Replacement
.
- Connect the high pressure fuel pump wiring harness.
- Install the fuel tank cap.
Note: If a fuel leak accrues at the fuel rail, the fuel rail will need to be replaced.
- Inspect for leaks using the following procedure:
13.1. | Turn ON the ignition, with the engine OFF for 2 seconds. |
13.2. | Turn OFF the ignition, for 10 seconds. |
13.3. | Turn ON the ignition, with the engine OFF. |
13.4. | Inspect for fuel leaks. |
- Install the pressure relief cap to the fuel feed pipe.
- Install the intake manifold. Refer to
Intake Manifold Replacement
.
- Install the high pressure fuel pump shield. Refer to
Fuel Pipe Shield Replacement
.