Fuel Injection Pump
Fuel Injection Pump
Removal
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.
WARNING: Clean all fuel residue from the engine compartment. If not removed, fuel residue may ignite when the engine is returned to operation. Failure to follow this instruction may result in serious personal injury.
WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
NOTICE: Do not loosen any fittings or plugs on the fuel injection pump.
1. Release the fuel system pressure.
2. NOTE: Use care when removing the fuel injection pump noise insulator. Spreading the openings will aid in removing the fuel injection pump noise insulator and reduce the risk of damage.
Remove the fuel injection pump noise insulator shield.
3. Disconnect the fuel injection pump electrical connector.
4. Disconnect the fuel jumper tube-to-fuel injection pump quick connect coupling.
5. Alternately loosen the 2 fuel injection pump bolts one complete revolution at a time.
- Discard the 2 fuel injection pump bolts.
- Remove the fuel injection pump.
- Remove and discard the fuel injection pump O-ring seal.
Installation
1. NOTE: The cam lobe for the fuel injection pump must be at Bottom Dead Center (BDC) for the fuel injection pump installation.
Remove the fuel injection pump roller tappet.
- Inspect the fuel injection pump roller tappet. For additional information, refer to Fuel Injection Pump Roller Tappet Inspection Procedures.
2. Remove the fuel injection pump mounting plate bolt and the fuel injection pump mounting plate.
3. Using the crankshaft pulley bolt, turn the crankshaft until the fuel injection pump cam lobe is at BDC (Bottom Dead Center).
4. NOTE: The valve cover is removed for clarity.
NOTE: Apply clean engine oil to the fuel injection pump mounting pedestal bore.
Install the fuel injection pump roller tappet.
5. NOTE: Apply clean engine oil to the fuel injection pump mounting plate seal.
Lubricate and install a new fuel injection pump mounting plate seal.
6. NOTE: Apply clean engine oil to the fuel injection pump mounting plate O-ring seals.
Lubricate and install 2 new fuel injection pump mounting plate O-ring seals.
7. NOTE: Make sure the mating surfaces are free of any dirt or foreign material.
NOTE: Apply clean engine oil to the fuel injection pump mounting plate bore.
Install the fuel injection pump mounting plate and loosely install the fuel injection pump mounting plate bolt.
8. NOTE: Apply clean engine oil to the fuel injection pump O-ring seal.
Lubricate and install a new fuel injection pump O-ring seal onto the fuel injection pump.
9. Install the fuel injection pump and loosely install 2 new fuel injection pump bolts.
1. Alternately tighten each bolt one complete revolution until seated.
2. Tighten each bolt to 20 Nm (177 lb-in).
3. Tighten each bolt an additional 45 degrees.
4. Tighten the fuel injection pump mounting plate bolt to 10 Nm (89 lb-in).
10. Connect the fuel jumper tube-to-fuel injection pump quick connect coupling.
11. Connect the fuel injection pump electrical connector.
12. NOTE: Use care when installing the fuel injection pump noise insulator. Spreading the openings will aid in installing the fuel injection pump noise insulator and reduce the risk of damage.
Install the fuel injection pump noise insulator shield.