Fuel Injection Pump Replacement

Fuel Injection Pump Replacement

Removal Procedure

1. Remove the center intake manifold. Refer to Center Intake Manifold Replacement Center Intake Manifold Replacement.

2. Remove 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. Disconnect the electrical connectors (1).

4. Collapse the hose clamps and remove the fuel return and fuel feed hoses (2).

5. Remove the engine cooling crossover housing Thermostat Housing Crossover Replacement (LGH) Thermostat Housing Crossover Replacement.




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





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

7. Rotate the crankshaft until the fuel injection pump gear timing marks are aligned with camshaft gear timing marks.

8. Remove the fuel injection pump bolts (1) and (2).

9. Remove the turbocharger cooler return pipe bracket (3).

10. Remove the fuel injection pump (4).

Note: If any metal debris is found, replace the following components: fuel injection pump, fuel rails, fuel injectors, fuel return line assembly, all high pressure fuel pipes, indirect fuel injector and fuel feed pipes (pump to indirect fuel injector).

11. Remove the fuel pressure regulator and inspect for metal debris on the end of the regulator tip.

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) and tighten to 75 Nm (55 lb ft).




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 (LGH) Thermostat Housing Crossover Replacement.

10. 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.

11. Install the center intake manifold. Refer to Center Intake Manifold Replacement Center Intake Manifold Replacement.