Fuel Injection Pump

Fuel Injection Pump Replacement

Removal Procedure




1. Remove the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement (LMM) (Thermostat Housing Crossover Replacement).
2. Remove the center intake manifold. Refer to Center Intake Manifold Replacement (Intake Manifold Replacement).
3. Reposition the fuel hose clamp (1) at the fuel return pipe.
4. Reposition the fuel hose clamp (2) at the fuel injection fuel feed manifold.




5. Reposition the fuel hose clamp (2) at the fuel injection pump.
6. Reposition the fuel hose clamp (3) at the fuel injection pump.
7. Remove the fuel hose (1) from the return pipe and injection pump.
8. Remove the fuel hose (4) from the fuel injection fuel feed manifold and injection pump.




9. Loosen the left fuel rail fuel feed pipe fittings (1).




10. Remove the left fuel rail fuel feed pipe.

Note: Be careful not to damage any mating surfaces.

11. Remove the fuel injection pump. Refer to Fuel Injection Pump Removal (76. Fuel Injection Pump Removal).

Preparing The Fuel Injection Pump

1. Hold the fuel pump by the drive gear in a vice with copper jaw liners.
2. Loosen the gear nut until the nut is even with the end of the gear shaft.
3. Remove the gear from the tapered shaft of the injection pump.
4. Separate the injection pump and adapter by removing the 3 bolts and spacers.
5. Inspect the O-ring for damage on the pump adapter and replace, if necessary. Lubricate the O-ring with clean engine oil.
6. Clean all mating surfaces.
7. Install the adapter on the pump.
Caution: Refer to Fastener Caution (Fastener Caution).

8. Install the 3 bolts and spacers.

Tighten the bolts to 20 Nm (15 lb ft).

9. Install the gear and nut.

Tighten nut to 70 Nm (52 lb ft).

Installation Procedure

1. Install the fuel injection pump. Refer to Fuel Injection Pump Installation (102. Fuel Injection Pump Installation).




2. Position the left fuel rail fuel feed pipe.




3. Tighten the left fuel rail fuel feed pipe fittings (1).

Tighten fittings to 41 Nm (30 lb ft).




4. Install the fuel hose (4) to the fuel injection fuel feed manifold and injection pump.
5. Install the fuel hose (1) from the return pipe and injection pump.
6. Position the fuel hose clamp (3) at the fuel injection pump.
7. Position the fuel hose clamp (2) at the fuel injection pump.




8. Position the fuel hose clamp (2) at the fuel injection fuel feed manifold.
9. Position the fuel hose clamp (1) at the fuel return pipe.
10. Install the center intake manifold. Refer to Center Intake Manifold Replacement (Intake Manifold Replacement).
11. Install the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement (LMM) (Thermostat Housing Crossover Replacement).
12. Prime the fuel system. Refer to Fuel System Priming (Fuel System Priming).
13. Start the engine. If the engine stalls, repeat the above step.
14. Once the engine starts, inspect for fuel leaks.