Removal

1. Disconnect both negative battery cables at both batteries.

Throttle Position Sensor Location:

2. Disconnect electrical connector at throttle position sensor on side of injection pump (if equipped with automatic transmission).

Electronic Components:

3. Disconnect the electrical connector at fuel shutdown solenoid.
4. Disconnect the main engine wiring harness at top of injection pump and position to the side.
5. Remove the metal intake manifold-to-intercooler connecting tube.

Air Heater:

6. Remove the engine oil dipstick tube mounting clamp and bolt. Position dipstick tube to the side.
7. Disconnect the air heater cables (two nuts) and remove the air heater assembly at intake manifold (five bolts). Discard both of the old air heater base gaskets.
8. Remove the throttle control bracket, cables and linkage assembly from the side of pump (three bolts). Position the assembly to the side.

Wastegate And Vacuum Lines:

9. Disconnect turbocharger wastegate line and vacuum line from air flow control (AFC) valve at rear of injection pump.

Fuel Injection Pump Supply Line:

10. Remove the fuel supply line at both ends (injection pump and fuel filter/water separator). For procedures, refer to Fuel Injection Pump Supply Line. Service and Repair Place a rag beneath the fitting to catch excess fuel.

Injection Pump Overflow Valve:

11. Remove the overflow valve and fuel return line at pump. Place a rag beneath the fitting to catch excess fuel.
12. Disconnect the six (6) high-pressure fuel lines from the fuel delivery valve holders at the top of injection pump. For procedures, refer to High-Pressure Fuel Lines. Service and Repair Place a rag beneath the fittings to catch excess fuel.

Engine Oil Supply Line And Pump Mounting Nuts:

13. Disconnect the engine oil supply line at side of pump.

Oil Fill Tube, Adapter, And Mounting Bracket:

14. Remove the oil fill tube bracket mounting bolt.
15. Remove oil fill tube from tube-to-gear housing adapter. This is removed by screwing counterclockwise from adapter.
16. Remove oil fill tube adapter from gear housing. Adapter is removed by screwing counter-clockwise from gear housing.

Timing Pin Location:

The engine is equipped with a built-on moveable timing pin. This pin is located above the power steering pump, below and to the inside of the fuel injection pump, on the rear of the cam gear housing.

Back Of Camshaft Gear:

The pin will engage into a machined hole in the back of the camshaft gear. It is designed to position the engine to TDC (Top Dead Center) on the compression stroke of number 1 cylinder.

17. Remove the rubber air tube connecting the turbocharger to the air filter housing. The engine can be rotated with a barring tool such as Snap-On No. SP371, MET No. 3377462 (Cummins Tool Division), or an equivalent.

Rotating Engine With Barring Tool:

18. The opening for the barring tool is located in the rear flange of engine on exhaust manifold side. Remove the rubber access plug covering this opening.
19. Insert the barring tool into the flywheel housing opening.
20. While holding tension on the timing pin (towards front of engine), very slowly rotate the engine (counter-clockwise as viewed from front) with the barring tool. Rotating the barring tool counter-clockwise will rotate the crankshaft clockwise. Continue to rotate until the timing pin drops into the machined hole in the back of the camshaft gear. When the pin aligns to the gear, the engine is now at the TDC position (compression stroke) at cylinder number 1.

CAUTION: When installing the fuel injection pump and to achieve proper injection pump timing, the engine MUST be in the TDC position (compression stroke) at cylinder number 1.

Before proceeding to the next step, and to prevent shearing of the timing pin, temporarily remove the timing pin from the back of the gear.

Injection Pump Gear, Washer, And Nut:

21. Remove the nut and washer retaining the injection pump gear to the injection pump shaft. Place a shop towel below the retainer nut in the gear housing cover opening to prevent the nut or washer from falling into the gear housing.

CAUTION: If the gear retainer nut or washer drops into gear housing, cover must be removed to retrieve them before engine is started.

Separating Injection Pump Gear From Pump Shaft:

22. Use a T-bar type puller to separate the injection pump gear from the injection pump shaft. Attach two M8 X 1.24 mm (metric) screws through the puller and into the two threaded holes supplied in the pump gear. Pull the injection pump gear forward until it loosens from the injection pump shaft. Pull on the gear only enough to loosen it from the injection pump shaft. Pulling the gear too far may cause damage or breakage to the gear cover.

Pump Mounting Bolts:

23. Remove the two (2) injection pump-to-lower mounting bracket bolts.

Engine Oil Supply Line And Pump Mounting Nuts:

24. Remove the four (4) injection pump-to-gear housing mounting nuts.
25. Remove the injection pump from gear housing. Take care not to nick the injection pump shaft on the aluminum gear housing when removing pump.
26. Clean the injection pump 0-ring mounting surfaces on both the gear housing and pump.