Solstice 2006-2008, Sky 2007-2008

High Pressure Fuel Pump

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Removal & Installation



2.0L (LNF) Engine

CAUTION
Gasoline or 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.


CAUTION
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the low and high side fuel system pressure.
  4.  
  5. Disconnect the engine wiring harness electrical connector from the high pressure fuel pump.
  6.  
  7. Remove the engine wiring harness clip from the high pressure fuel pump cover.
  8.  
  9. Remove the high pressure fuel pump cover bolts.
  10.  
  11. Remove the high pressure fuel pump cover.
  12.  
  13. Remove the high pressure fuel pump insulator.
  14.  
  15. Loosen the fuel feed pipe to fuel pump fitting.
  16.  
  17. Remove the fuel feed pipe bolts.
  18.  
  19. Remove the fuel feed pipe from the intake manifold.
  20.  
  21. Loosen the high pressure fuel pipe fitting at the fuel pump.
  22.  
  23. Loosen the high pressure fuel pipe fitting at the fuel rail.
  24.  
  25. Remove and discard the high pressure fuel pipe.
  26.  
  27. Remove and discard the high pressure fuel pump bolts.
  28.  
  29. Remove the high pressure fuel pump.

    Click image to see an enlarged view

    Fig. High pressure fuel pump removal 2.0L (LNF) engine

  30.  
  31. Remove and discard the high pressure fuel pump gasket.
  32.  
  33. Remove and discard the high pressure fuel pump O-ring.
  34.  
  35. Remove the high pressure fuel pump roller lifter, if necessary.

    Click image to see an enlarged view

    Fig. High pressure fuel pump roller lifter 2.0L (LNF) engine

  36.  

To install:

  1. Lubricate the high pressure fuel pump cylinder head bore and roller lifter with silicon free engine oil.
  2.  
  3. Install the high pressure fuel pump roller lifter, if necessary.
  4.  
  5. Install a new high pressure fuel pump O-ring.
  6.  
  7. 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.

  8.  
  9. Install the high pressure fuel pump. Push the pump into the cylinder head bore by hand, applying force to the top of the pump.
  10.  
  11. Install the new high pressure fuel pump bolts hand tight.
  12.  
  13. Ensure that the high pressure fuel pump, and fuel rail fittings are clean prior to assembly.
  14.  
  15. Lubricate the high pressure fuel pump, and the fuel rail fittings with silicon free engine oil.
  16.  
  17. Install the new high pressure fuel pipe.
  18.  
  19. Tighten the high pressure fuel pipe fitting to the fuel rail hand tight.
  20.  
  21. Tighten the high pressure fuel pipe fitting to the fuel pump hand tight.
  22.  
  23. Place the fuel feed pipe onto the intake manifold.
  24.  
  25. Install the fuel feed pipe bolts hand tight.
  26.  
  27. Tighten the fuel feed pipe to fuel pump fitting hand tight.
  28.  
  29. Tighten the fuel feed pipe bolts to 89 inch. lbs. (10 Nm).
  30.  
  31. Tighten the fuel feed pipe to fuel pump fitting to 22 ft. lbs. (30 Nm).
  32.  
  33. Tighten the high pressure fuel pipe fittings to 24 ft. lbs. (32 Nm).
  34.  
  35. Tighten the high pressure fuel pump bolts evenly to 11 ft. lbs. (15 Nm).
  36.  
  37. Install the high pressure fuel pump insulator.
  38.  
  39. Position the high pressure fuel pump cover.
  40.  
  41. Install the high pressure fuel pump cover bolts and tighten to 89 inch. lbs. (10 Nm).
  42.  
  43. Connect the engine wiring harness electrical connector to the high pressure fuel pump.
  44.  
  45. Install the engine wiring harness clip to the fuel pump cover.
  46.  
  47. Inspect for fuel leaks through the following steps:

    Turn ON the ignition, with the engine OFF for 2 seconds.
     
    Turn the ignition to the OFF position for 10 seconds.
     
    Turn ON the ignition, with the engine OFF.
     
    Check for fuel leaks.
     

  48.  
  49. Install the low side fuel pressure service port cap.
  50.  
  51. Tighten the fuel fill cap.
  52.  
  53. Install the intake manifold cover.
  54.  

 
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