Topic: Looks like I got bitten by the other somewhat common failure

[elff]

Got a P0087 code and Eng Pwr Reduced on the DIC.

Completely put the car into limp mode.  From all accounts, it looks like I need a new HPFP.

Anyone have the PDF for replacing this?  Even without that, it does not look to be that complicated.  Just have to remove that cowl under the windshield wipers and you then have complete access to it.

[elff]

T.S. to the rescue without even having to post a reply

http://www.skyroadster.com/forums/f5/p0087-p0089-how-replace-high-pressure-fuel-pump-51705/

http://www.kappaperformance.com/forum/index.php/topic,8564.msg133933.html#msg133933


Removal Procedure
1. Relieve the low and high side fuel system pressure. Refer to FuelPressure Relief.
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 Cautionin the Preface section.
14. Tighten the fuel feed pipe to fuel pump fitting hand tight.
14.1. Tighten the fuel feed pipe bolts to 10 N·m (89 lb in).
14.2. Tighten the fuel feed pipe to fuel pump fitting to 30 N·m (22 lb ft).
14.3. Tighten the high pressure fuel pipe fittings to 32 N·m (24 lb ft).
14.4. Tighten the high pressure fuel pump bolts evenly to 15 N·m (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 N·m (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:
20.1. Turn ON the ignition, with the engine OFF for 2 seconds.
20.2. Turn OFF the ignition, for 10 seconds.
20.3. Turn ON the ignition, with the engine OFF.
21. Install the low side fuel pressure service port cap.
22. Tighten the fuel fill cap.

Fuel Pressure Relief
Warning: Fuel that flows out at high pressure can cause serious injury to the skin and eyes.
ALWAYS depressurize the fuel system before removing components that are under high fuel
pressure.

1. Install a scan tool to the vehicle and command the fuel pump relay OFF, allowing the low
pressure fuel pump to shut off.
2. Start the vehicle and allow the engine to idle until the engine stops. The engine will stop in
approximately 20-30 seconds.
3. Turn the ignition OFF.
4. Using the scan tool, verify that there is little to no fuel pressure, if there still is fuel pressure
repeat step 2.
Note: If a scan tool is not available, WAIT at LEAST 2 hours after the engine has been run,
before removing the high pressure fuel line.
5. Remove the high pressure fuel line.

[TomatoSoup]

Damn!  I wish *I* could remember all those replies

[elff]

HAHAHA
Well as usual,
You Da Man!!!!

[elff]

Just to confirm
Is this the correct part for the HPFP in the engine bay?
FUEL PUMP - 2008 SATURN SKY (12658478)
HPFP from Crate Engine Depot Clicky Clicky

[LatinVenom]

elff.
Before you go through all the trouble, you need to see the connector and clean it. This is what GHOST did on the BB and his problems went away.
This was a suggestion of one of the people that work at GM.
You may want to look at his post on the BB.
Just and FYI.

[elff]

Do you have a direct link to that post?

[TomatoSoup]

Do you have a direct link to that post?

T.S. to the rescue -- http://www.solsticeforum.com/forum/f59/p2188-commonalities-130313/#post1878026

[sirwm]

Just to confirm
Is this the correct part for the HPFP in the engine bay?
FUEL PUMP - 2008 SATURN SKY (12658478)
HPFP from Crate Engine Depot Clicky Clicky

is this the right part ?    wow -- $489+   

[elff]

Yup

Cleaning did not help.  Will order the part and replace it.

[Jim]

Quite a few GM dealers on eBay have them for less than $400 shipped.

[roxer]

Rockauto. Better price.

[Jim]

Rockauto. Better price.

That is a good price!

[elff]

Sure is.
Part is ordered and I added FedEx 2 day shipping for only $6.99
I'll have this replaced this weekend and then I have a certain corvette I need to track down and teach a lesson.

[Sol Asylum]

Don't be so picky, teach all the Corvettes a lesson.

[elff]

I do try.

[Kelu]

I'll have this replaced this weekend and then I have a certain corvette I need to track down and teach a lesson.

That means you lost to him at first meet? Whatta disappointment for Kappa community.

  Nice to hear that you are tracking down Vettes, that means Lusi is strong again.

[elff]

I cleared him by a full car length and was starting to pull more and then I lost all power, engine light and got this lovely message

[elff]

This is one of the easier parts to replace.  Tall people who don't have to sit in the engine bay, would have zero issues. 

[elff]

So in order to do this work, I needed the following tools.
Christmas Tree plug puller
7mm socket
10mm socket
15mm socket
17mm open ended wrench

Start by removing the windshield wipers. 
15MM nut and pop off the fluid tubes by firmly pulling them straight up
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Then pop off 6 Christmas Tree pushpins
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Remove the bolts for the rest of the cowl
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and just slide the cowl up.  I did not remove the fluid tube going to the washer bottle as I had enough room at this point

Remove this bracket [it should have 3 10MM bolts, looks like one of mine never made it back during the engine build]
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Remove the sound insulator
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Remove the bolts holding down this thingamabob and unclip your Fuel filter if you have one,  Then move them out of the way.
Have a shop towel handy as this will have fuel in it.   Please note the Valve.  Use that to bleed the pressure from the system before you begin.   Oooops that's step 1.
 
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Loosen the connectors for the fuel lines using the 17MM open ended wrench, then remove the 10mm bolts holding the fuel pump to the engine and remove the Fuel pump.  It takes a little wiggling but it comes off easy enough
Place it aside
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Clean up the area it mounts to before instilling the new pump.
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Grab your new fuel pump and install it
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Make sure you torque it to spec
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[elff]

I can see why they added that noise insulator, the HPFP is a noisy little bugger. 
Of course make sure nothing is leaking before you put everything back together.

https://vimeo.com/183197179

[DeepBlueGXP]

code gone?

[Sly Bob]

Nice post and yeah, did that fix it?

[elff]

It sure did.
before replacing the HPFP, I could not rev the engine without the code resetting?

I took it out for a test drive and thrashed it with no issues

[Kelu]

Nice to see instructions for this operation and more important to read that you fix it  way to go little brother