Fuel Pump Replacement

Fuel Pump Replacement

Removal Procedure




1. Relieve the low and high side fuel system pressure. Refer to Fuel Pressure Relief (Low Pressure with CH 48027) (Fuel Pressure Relief (Low Pressure with CH 48027))Fuel Pressure Relief (High Pressure Side) (Fuel Pressure Relief (High Pressure Side))Fuel Pressure Relief (Low Pressure without Special Tool) (Fuel Pressure Relief (Low Pressure without Special Tool))Fuel Pressure Relief (Low Pressure Side with CH 48027-100) (Fuel Pressure Relief (Low Pressure Side with CH 48027-100)).
2. Disconnect the engine wiring harness electrical connector (1) from the high pressure fuel pump.
3. Remove the engine wiring harness clip (3) from the high pressure fuel pump cover.




4. Remove the high pressure fuel pump cover bolts.
5. Remove the high pressure fuel pump cover.




6. Remove the high pressure fuel pump insulator.




7. Loosen the fuel feed pipe to fuel pump fitting.
8. Remove the fuel feed pipe bolts.
9. Remove the fuel feed pipe from the intake manifold.




10. Loosen the high pressure fuel pipe fitting at the fuel pump.
11. Loosen the high pressure fuel pipe fitting at the fuel rail.
12. Remove and discard the high pressure fuel pipe.




13. Remove and discard the high pressure fuel pump bolts.
14. Remove the high pressure fuel pump.
15. Remove and discard the high pressure fuel pump gasket.
16. Remove and discard the high pressure fuel pump O-ring.




17. Remove the high pressure fuel pump roller lifter, if necessary.

Installation Procedure




1. Lubricate the high pressure fuel pump cylinder head bore and roller lifter with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.
2. Install the high pressure fuel pump roller lifter, if necessary.




3. Install a NEW high pressure fuel pump O-ring.
4. Position the NEW high pressure fuel pump gasket to the cylinder head.

Note: Ensure the plastic bolt retainers are installed in the high pressure fuel pump mounting holes prior to installing.

5. Install the high pressure fuel pump. Push the pump into the cylinder head bore by hand, applying force to the top of the pump.
6. Install the NEW high pressure fuel pump bolts hand tight.
7. Ensure that the high pressure fuel pump, and fuel rail fittings are clean prior to assembly.
8. Lubricate the high pressure fuel pump, and the fuel rail fittings with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.




9. Install the NEW high pressure fuel pipe.
10. Tighten the high pressure fuel pipe fitting to the fuel rail hand tight.
11. Tighten the high pressure fuel pipe fitting to the fuel pump hand tight.




12. Place the fuel feed pipe onto the intake manifold.
13. Install the fuel feed pipe bolts hand tight.

Caution: Refer to Fastener Caution (Fastener Caution).

14. Tighten the fuel feed pipe to fuel pump fitting hand tight.

1. Tighten the fuel feed pipe bolts to 10 Nm (89 lb in).
2. Tighten the fuel feed pipe to fuel pump fitting to 30 Nm (22 lb ft).
3. Tighten the high pressure fuel pipe fittings to 32 Nm (24 lb ft).
4. Tighten the high pressure fuel pump bolts evenly to 15 Nm (11 lb ft).




15. Install the high pressure fuel pump insulator.




16. Position the high pressure fuel pump cover.
17. Install the high pressure fuel pump cover bolts and tighten to 10 Nm (89 lb in).




18. Connect the engine wiring harness electrical connector (1) to the high pressure fuel pump.
19. Install the engine wiring harness clip (3) to the fuel pump cover.
20. 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.

21. Install the low side fuel pressure service port cap.
22. Tighten the fuel fill cap.