Injection Pump Replacement

Injection Line Routing:

Pump Drive Gear Bolts:

Injection Pump Locating Pin:

CAUTION: Never engage the starter motor to rotate the engine when the injection pump is removed as severe engine damage will occur. With the injection pump removed the pump driven gear could jam in the front housing by engaging the starter motor, resulting in a sheared crankshaft or camshaft gear key and possible valvetrain damage. Always bar the engine over by hand to avoid internal damage.

- Scribe or paint a mark on the front cover and the injection pump flange.
- Rotate the engine to gain access to the bolts that hold the driven gear to the injection pump.
- Access is gained through the oil filler neck hole.

NOTE: Removing the fuel injection pump and injection lines requires removing the intake manifold.

REMOVE OR DISCONNECT
1. Negative battery cable.
2. Intake manifold. Refer to Intake Manifold. Service and Repair
3. Injection lines. Refer to Injector Line Replacement. Service and Repair
4. Fuel inlet line from the injection pump.
5. All necessary harness connectors and hoses from the injection pump.
6. Fuel return line at the top of the injection pump.
7. Oil fill tube.
8. Grommet for oil filler tube.
9. Bolts.
10. Flange nuts.
11. Pump. Cap all open lines and nozzles.
12. Gasket.

INSTALL OR CONNECT
1. New gasket.

NOTE: Be sure the locating pin on the pump hub goes into the slotted hole in the driven gear and not the hole in the gear.

2. Injection pump to the front cover.
- Align the locating pin on the pump hub with the slot in the injection pump driven gear.

3. Flange nuts.

Tighten
- Nuts to 40 Nm (30 lb. ft.).

4. Drive gear to injection pump bolts.

Tighten
- Bolts to 25 Nm (20 lb. ft.).

5. Grommet for oil filler tube.
6. Oil filler tube.
7. Fuel feed line at the injection pump.

Tighten
- Fitting to 25 Nm (20 lb. ft.).

8. Fuel return line to the top of the injection pump.
9. All necessary harness connectors.
10. Injection lines. Refer to Injector Line Replacement. Service and Repair
11. Intake manifold. Refer to Intake Manifold Replacement. Service and Repair
12. Negative battery cables.
13. Adjust injection timing. Refer to Checking or Adjusting Injection Timing. Adjustments