Diesel MFI Pump: Service and Repair
REMOVAL1. Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2. Disconnect battery ground cables from both batteries.
3. Remove engine cover.
Cover Plate:
4. Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts:
5. Remove bolts attaching injection pump to drive gear.
6. Disconnect electrical connectors to injection pump.
Injection Pump:
7. Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
8. Disconnect accelerator cable and speed control cable from throttle lever.
9. Remove air cleaner assembly and duct.
10. Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
11. Disconnect fuel inlet line and return line from the fuel filter. Remove fuel filter bracket attaching bolts and remove fuel filter and bracket as an assembly.
Fuel Return Line:
12. Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
13. Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
14. Remove fuel injection lines from nozzles and cap lines and nozzles.
15. Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
16. Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump:
17. If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump:
18. Remove injection pump through passenger compartment using care to avoid spilling fuel inside vehicle.
INSTALLATION
1. Install new o-ring onto drive gear end of injection pump.
2. Install injection pump from passenger compartment. Move injection pump down and into position using care to avoid spilling diesel fuel inside vehicle.
3. Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts:
4. Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump:
5. Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6. If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7. Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8. Remove caps and connect fuel filter-to-injection pump fuel line.
9. Install fuel filter and bracket as an assembly and tighten bolts to 33-52 Nm (24-39 ft lb). Install fuel filter return and inlet fuel lines.
10. Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11. Install air cleaner assembly and duct.
12. Connect accelerator and speed control cables to throttle lever.
13. Install fast idle solenoid and bracket assembly.
14. Install electrical connectors on injection pump.
15. Clean adapter housing cover plate sealing surfaces.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16. Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17. Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18. Run engine and check for fuel leaks.
19. Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20. Check and adjust injection pump timing.