Fuel Injection Pump Installation
^ Tools Required- J 29873 Nozzle Socket
1. Install the fuel injection pump and gasket with the ESO solenoid pointed straight up.
IMPORTANT: 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.
2. Install the fuel injection pump nuts.
^ Tighten the nuts to 40 Nm (30 ft. lbs.).
NOTICE: Refer to Fastener Notice in Service Precautions.
3. 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.
4. Install the fuel injection pump gear retaining bolts.
^ Tighten the bolts to 25 Nm (20 ft. lbs.).
IMPORTANT: 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.
5. Apply a thin coating of GM P/N 14001899, or equivalent, to the threads of the injection nozzle.
NOTICE: In order to remove or install an injection nozzle, use the J 29873 Nozzle Socket on the 30-mm portion of the nozzle. Failure to use the 30-mm hex portion will result in damage to the injection nozzle
6. Install the injection nozzle and gasket, using the J 29873.
^ Tighten the nozzle to 80 Nm (59 ft. lbs.).
7. Install the injection line brackets.
8. Install the injection lines to the pump.
IMPORTANT:
^ Uncap the injection lines before assembly.
^ Install the injection lines in the correct position.
^ Do not bend the injection lines.
9. Install the injection lines to the nozzles.
^ Tighten the injection line fittings to 36 Nm (28 ft. lbs.).
IMPORTANT:
^ Uncap the injection lines before assembly.
^ Install the injection lines in the correct position.
^ Do not bend the injection lines.
10. Install the injection line clips to the brackets.
11. Install the fuel inlet line to the fuel injection pump.
12. Install the fuel return hose to the fuel injection pump.
13. Install the fuel return line brackets on the front left and the front right side rocker covers.
14. Install the fuel return hoses at the injector nozzles.
15. Install the clamps.