Diesel Fuel Injection Pump Service and Repair

REMOVAL PROCEDURE
1. Disconnect the negative battery cables.
2. Remove the intake manifold. Refer to Intake Manifold Removal.
3. Disconnect the injection lines. Refer to Injection Lines (Diesel).
4. Disconnect the fuel inlet line from the injection pump.
5. Disconnect all of the necessary harness connectors and the hoses from the injection pump.
6. Disconnect the fuel return line at the top of the injection pump.
7. Disconnect the oil fill tube.
8. Remove the grommet from the oil tiller tube.







9. Rotate the engine in order to gain access to the bolts (1) that hold the driven gear to the injection pump. The access is gained through the oil filler neck hole.

IMPORTANT: Never engage the starter motor in order 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 valve train damage. Always bar the engine over by hand in order to avoid internal engine damage.

10. Remove the driven gear bolts.
11. Remove the injection pump flange nuts. Use wrench J 41069.
12. Remove the injection pump.
13. Cap all of the open lines and nozzles.
14. Remove the flange gasket.

INSTALLATION PROCEDURE
1. Install the new flange gasket on the injection pump.






IMPORTANT: Be sure that the locating stud (1) on the injection pump hub goes into the slotted/elongated hole in the driven gear.

2. Adjust the locating stud (1) to the proper position in order to match with the slotted/elongated hole in the driven gear.







3. Install the injection pump, making sure the locating stud is positioned within the slotted/elongated hole (3) in the driven gear.
4. Install the injection pump flange nuts.

Tighten
- Tighten the nuts to 40 Nm (30 lb ft).

IMPORTANT: None of the driven gear bolts should be torqued until all of the bolts are installed. This will allow for proper alignment of all of the bolt holes.







5. Install the driven gear bolts (1).

Tighten
- Tighten the bolts to 25 N.m (18 lb ft).

6. Install the grommet for the oil filler tube.
7. Connect the oil filler tube.
8. Connect the fuel feed line at the injection pump.
9. Connect the fuel return line to the top of the injection pump.
10. Connect all of the necessary harnesses and connectors.
11. Connect the injection lines. Refer to the tags on the lines. Refer to Injection Lines (Diesel).
12. Install the intake manifold. Refer to Intake Manifold Installation.
13. Connect the negative battery cables.
14. Adjust the injection timing. Refer to Checking/Adjust Injection Timing. Adjustments