You park your truck and notice leaking oil coming from the underside. Keeping calm, you pop the hood and check all the normal places where there might be a leak. Then you notice oil gathered on the high pressure oil pump (HPOP). You scratch your head and take out your wallet, knowing the plug where the oil is leaking from is non-serviceable as you wonder how much a new pump will cost.
Put Your Wallet Away And Replace The Plug
You can replace the manufacturer’s short-threaded plug with a longer threaded plug with a little time and effort. Most repair HPOP kits will give you the new plug, an O-ring and Loctite packet. Here are some easy instructions to repair your high pressure oil pump.
Step 1: Remove the pump from your vehicle so you can work on it. Lay it on a flat and stable surface with the nose down and the injector pressure regulator facing upward.
Step 2: Remove the injector pressure regulator with a 1-1/8 inch deep well socket and take out the old non-serviceable plug with a 13mm wrench. Find and remove the small plastic check ball.
Step 3: If your stock pump was made in a model year before 1996, you will not see a metal edge filter in the pump. All models from 1996 to 2003 will have the edge filter. Push the edge filter all the way inside past the pocket that holds the check ball.
Step 4: Place the check ball into the injector pressure regulator hole so it rests in the pocket. Place a small amount of Loctite on the plug.
Step 5: Use the 13mm wrench to install the new plug in the plug hole. Never over-tighten the plug as the o-ring boss thread makes contact with the metal.You’ll know that you’ve installed everything correctly when you see the plug hold the filter and check ball in place.
Step 6: Replace the injector pressure regulator and reinstall the high pressure oil pump in your vehicle.