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Fuel Pump Replacement




Fuel Pump Replacement

Special Tools

EN-48896 HP Fuel Pump Installation Alignment Gage

Removal Procedure

1. Relieve the low and high side fuel system pressure. Refer to Fuel Pressure Relief (with CH 48027-100) (Service and Repair)Fuel Pressure Relief (w/o CH 48027-100) (Service and Repair).
2. Remove the drive motor generator power inverter module. Refer to Drive Motor Generator Power Inverter Module Removal and Installation (Drive Motor Generator Power Inverter Module Removal and Installation).
3. Remove the high pressure fuel pump shield. Refer to Fuel Pipe Shield Replacement (Service and Repair).
4. Remove the upper intake manifold. Refer to Upper Intake Manifold Replacement (LY7) (Service and Repair)Upper Intake Manifold Replacement (LCS) (Service and Repair).




5. Disconnect the engine wiring harness electrical connector from the high pressure fuel pump.
6. Remove the radiator surge tank outlet pipe. Refer to Radiator Surge Tank Outlet Hose/Pipe Replacement (LZ4) (Service and Repair)Radiator Surge Tank Outlet Hose/Pipe Replacement (LY7) (Service and Repair)Radiator Surge Tank Outlet Hose/Pipe Replacement (LAT) (Service and Repair)Radiator Surge Tank Outlet Hose/Pipe Replacement (LE5) (Service and Repair)
7. Remove the low pressure feed pipe. Refer to Fuel Feed Pipe Replacement (Service and Repair).
8. Remove the high pressure pipe. Refer to Fuel Feed Intermediate Pipe Replacement (Service and Repair). Discard this pipe.
9. Remove and discard the high pressure fuel pump bolts (1).
10. Remove the high pressure fuel pump (2).
11. Remove and discard the high pressure fuel pump O-ring (3).
12. Remove and discard the high pressure fuel pump gasket (4).
13. Remove the high pressure fuel pump roller lifter (5).

Installation Procedure

Note: The camshaft must be in the base circle position before the high pressure fuel pump is installed.

1. Use the EN-48896 to ensure that the camshaft lobe is in the base circle position. At base circle the tool will be flush with the head.
2. 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.





Note: The high pressure fuel pump gasket has a retaining feature to hold the pump retaining bolts in place.

4. Install the high pressure fuel pump roller lifter (5).
5. Install a NEW high pressure fuel pump O-ring (3).
6. Position the NEW high pressure fuel pump gasket (4) and bolts (1) to the fuel pump.
7. Install the high pressure fuel pump (2). Force will be required while hand tightening the bolts.

Caution: Refer to Fastener Caution (Fastener Caution).

8. Tighten the high pressure fuel pump retaining bolts to 15 Nm (11 lb ft).
9. Ensure the high pressure fuel pump and fuel rail fittings are clean prior to assembly.
10. Install a NEW high pressure fuel pipe. Refer to Fuel Feed Intermediate Pipe Replacement (Service and Repair).
11. Install the fuel feed pipe to the high pressure fuel pump. Refer to Fuel Feed Pipe Replacement (Service and Repair).
12. Connect the high pressure fuel pump wiring harness.
13. Install the radiator surge tank outlet pipe. Refer to Radiator Surge Tank Outlet Hose/Pipe Replacement (LZ4) (Service and Repair)Radiator Surge Tank Outlet Hose/Pipe Replacement (LY7) (Service and Repair)Radiator Surge Tank Outlet Hose/Pipe Replacement (LAT) (Service and Repair)Radiator Surge Tank Outlet Hose/Pipe Replacement (LE5) (Service and Repair).
14. Install the fuel tank cap.

Note: If a fuel leak accrues at the fuel rail, the fuel rail will need to be replaced.

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. Install the pressure relief cap to the fuel feed pipe.
17. Install the upper intake manifold. Refer to Upper Intake Manifold Replacement (LY7) (Service and Repair)Upper Intake Manifold Replacement (LCS) (Service and Repair).
18. Install the high pressure fuel pump shield. Refer to Fuel Pipe Shield Replacement (Service and Repair).
19. Install the drive motor generator power inverter module. Refer to Drive Motor Generator Power Inverter Module Removal and Installation (Drive Motor Generator Power Inverter Module Removal and Installation).

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