Fuel Pump Replacement

Callout	Component Name
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. Preliminary Procedures Relieve the fuel system pressure - Refer to Fuel Pressure Relief Refer to Fuel Pump Insulator Replacement Disconnect the fuel feed pipe at the fuel pump - Refer to Fuel Feed Front Pipe Replacement Remove and DISCARD the fuel feed intermediate pipe - Refer to Fuel Feed Intermediate Pipe Replacement 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.
1	Fuel Pump Bolt[2x] CAUTION: Refer to Fastener Caution . 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. 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. Procedure Remove and DISCARD the fuel pump bolts. Add threadlocker to the NEW fuel pump bolts - Refer to Adhesives, Fluids, Lubricants, and Sealers Tighten First Pass: 8 N.m (71 lb in) Final Pass: 50 degrees
2	Fuel Pump Procedure Install the EN-50790 alignment gauge and turn the crankshaft until the camshaft lobe is at the base circle position. NOTE: Ensure that during removal of the fuel pump that the valve lifter follower does NOT fall apart. The camshaft MUST be at the base circle position before the fuel pump is installed. At the base circle position, the EN-50790 alignment gauge will sit flush with the cylinder head. Special Tools EN-50790 Fuel Pump Installation Alignment Gauge Equivalent regional tools: Refer to Special Tools
3	Fuel Pump Gasket Procedure Remove and DISCARD the fuel pump gasket. Install the NEW fuel pump gasket with the locating tab pointing upwards.
4	Valve Lifter Follower Procedure Lubricate the engine cylinder head bore and valve lifter follower with clean engine oil - Refer to Adhesives, Fluids, Lubricants, and Sealers 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.