Fuel Pump: Service and Repair

NOTE: Some diesel engines may exhibit a condition of hard cold starts. If this condition exists, check the fuel pump housing for a crack in the area where the fuel line is connected to the fuel pump, which may allow air to enter the system. The cracked fuel pump housing could be caused by the fuel line vibrating. To correct this condition, remove the righthand thermostat housing bolt and install stud, part No. 6270979. Disconnect fuel line at the fuel pump and install clip, part No. 343463 onto fuel line. Install washer face nut, part No. 10008001. Replace the fuel pump and connect the fuel line.

1. Disconnect fuel lines and electrical connectors from pump.
2. Remove fuel pump mounting bolts and the fuel pump.
3. Remove all gasket material from the pump and block gasket surfaces. Apply sealer to both sides of new gasket.
4. Position gasket on pump flange and hold pump in position against its mounting surface. Make sure rocker arm is riding on crankshaft eccentric.
5. Press pump tight against its mounting. Install retaining screws and tighten them alternately.
6. Connect fuel lines. Then operate engine and check for leaks.

NOTE: Before installing the pump, it is good practice to crank the engine so that the nose of the crankshaft eccentric is out of the way of the fuel pump rocker arm when the pump is installed. In this way there will be the least amount of tension on the rocker arm, thereby easing the installation of the pump.