Fuel Injection Pump Replacement

Fuel Injection Pump Replacement

Removal Procedure

1. Remove the center intake manifold. Refer to Center Intake Manifold Replacement (Service and Repair).
2. Remove and reposition the high pressure fuel pipes from the fuel injection pump. Refer to Fuel High Pressure Pipe Replacement - Rail to Rail (Fuel High Pressure Pipe Replacement - Rail to Rail) and Fuel High Pressure Pipe Replacement - Pump to Rail (Fuel High Pressure Pipe Replacement - Pump to Rail).
3. Remove and reposition the indirect fuel injector feed pipe from the injection pump. Refer to Fuel Feed Pipe Replacement (Pump to Indirect Fuel Injector) (Fuel Feed Pipe Replacement (Pump to Indirect Fuel Injector)).




4. Disconnect the electrical connectors (1).
5. Collapse the hose clamps and remove the fuel return and fuel feed hoses (2).
6. Remove the engine cooling crossover housing Thermostat Housing Crossover Replacement (LML) (Service and Repair).




7. Remove the camshaft gear access hole plug (1).





Note: The fuel pump must be correctly timed to the camshaft gear.

8. Rotate the crankshaft until the fuel injection pump gear timing marks are aligned with camshaft gear timing marks.
9. Remove the fuel injection pump bolts (1) and (2).
10. Remove the turbocharger cooler return pipe bracket (3).
11. Remove the fuel injection pump (4).

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.
Caution: Refer to Fastener Caution (Fastener Caution).

7. Install the adapter on the pump.
8. Install the 3 bolts and spacers and tighten to 20 Nm (15 lb ft).
9. Install the gear and nut and tighten to 70 Nm (52 lb ft).

Installation Procedure





Note: The fuel pump must be correctly timed to the camshaft gear.

1. Rotate the crankshaft to align the camshaft gear timing marks with the center of the inspection hole
2. Lubricate the O-ring on the fuel injection pump adapter with engine oil.
3. Install the fuel injection pump and adapter assembly (4) so that the timing mark on the fuel pump gear (5) is aligned with the timing marks on the camshaft gear (6).
4. Install the turbocharger cooler return pipe bracket (3).
Caution: Refer to Fastener Caution (Fastener Caution).

5. Install the fuel injection pump bolts (1) and (2) and tighten to 25 Nm (18 lb ft).




6. Install the camshaft gear access hole plug (1).




7. Connect the electrical connectors (1).
8. Collapse the hose clamps and install the fuel return and fuel feed hoses (2).
9. Install the engine cooling crossover housing Thermostat Housing Crossover Replacement (LML) (Service and Repair).
10. Install the indirect fuel injector feed pipe from the injection pump. Refer to Fuel Feed Pipe Replacement (Pump to Indirect Fuel Injector) (Fuel Feed Pipe Replacement (Pump to Indirect Fuel Injector)).
11. Install the high pressure fuel pipes from the fuel injection pump. Refer to Fuel High Pressure Pipe Replacement - Rail to Rail (Fuel High Pressure Pipe Replacement - Rail to Rail) and Fuel High Pressure Pipe Replacement - Pump to Rail (Fuel High Pressure Pipe Replacement - Pump to Rail).
12. Install the center intake manifold. Refer to Center Intake Manifold Replacement (Service and Repair).