Diesel Fuel Pump Service and Repair

REMOVAL

CAUTION: The fuel injection pump is an electronically controlled device. Handle carefully in order to prevent damage to internal and external components.

1. Remove the three bolts from the fuel injection pump timing gear.





2. Remove the fuel injection pump timing gear.





3. Remove the three fuel injection pump mounting nuts.

CAUTION: Never rotate the engine with the starter, the starter location engine rotation fixture, or with the wrench from the front of the engine with the fuel injection pump removed. The loose fuel pump drive gear could become lodged in the front cover and cause gear tooth distress and shear the camshaft drive gear. Align the camshaft gear timing marks before installing the fuel injection pump drive gear.





4. Remove the fuel injection pump.
5. Remove the fuel injection pump gasket.

INSTALLATION

CAUTION: Never rotate the engine with the starter, the starter location engine rotation fixture, or with the wrench from the front of the engine with the fuel injection pump removed. The loose fuel pump drive gear could become lodged in the front cover and cause gear tooth distress and shear the camshaft drive gear. Align the camshaft gear timing marks before installing the fuel injection pump drive gear.

1. Install the gasket to the front cover.
2. Install the fuel injection pump.
3. Install the electronic fuel injection pump with the ESO straight up.
4. Install the pump mount nuts.
- Tighten the nuts to 40 Nm (30 ft. lbs.).
5. Install the fuel injection pump gear. Align the slot in the fuel injection pump gear with the locating pin on the fuel injection pump hub.

NOTE: Align the timing marks. Be certain the mark on the fuel injection pump gear is aligned with the mark on the camshaft gear. For the proper timing of the fuel injection pump, the cam gear timing mark must be in the 12 o'clock position. Rotate the crankshaft to bring the cam gear timing mark up to the 12 o'clock position.

6. Install the fuel injection pump gear retaining bolts.
- Tighten the bolts to 25 Nm (20 ft. lbs.).
7. Install the wires and hoses at the fuel injection pump.