Injection Line Routing
Pump Drive Gear Bolts
Injection Pump Locating Pin

CAUTION: Never engage the starter motor to rotate the engine when the injection pump is removed as severe engine damage will occur. With the injection pump removed the pump driven gear could jam in the front housing by engaging the starter motor, resulting in a sheared crankshaft or camshaft gear key and possible valve train damage. Always bar the engine over by hand to avoid internal damage.
NOTE : Removing the fuel injection pump and injection lines requires removing the intake manifold.
Removal Procedure

  1. Remove the negative battery cables.
  2. Remove the intake manifold. Refer to Intake Manifold Removal .
  3. Remove the injection lines. Refer to Injection Lines .See: Fuel Injector Line\Service and Repair
  4. Remove the fuel inlet line from the injection pump.
  5. Remove all necessary harness connectors and hoses from the injection pump.
  6. Remove the fuel return line at the top of the injection pump.
  7. Remove the oil fill tube.
  8. Remove the grommet for oil filler tube.
  9. Rotate the engine to gain access to the bolts (1) that hold the driven gear to the injection pump. Access is gained through the oil filler neck hole.
  10. Remove the driven gear bolts.
  11. Remove the injection pump flange nuts. Use wrench J 41069.
  12. Remove the injection pump.
  13. Cap all open lines and nozzles.
  14. Remove the flange gasket.

Installation Procedure

  1. Install the new flange gasket on the injection pump.
  2. Adjust locating stud (1) to proper position to match with the slotted/elongated hole in driven gear.

Important: Be sure the locating stud (1) on the injection pump hub goes into the slotted/elongated hole in the driven gear.

  1. Install the injection pump making sure the locating stud is positioned within the slotted/elongated hole (3) in the driven gear.
  2. Install the injection pump flange nuts.

Tighten
Tighten nuts to 40 Nm (30 lb. ft) .
Important: All driven gear bolts should not be torqued until all bolts are installed. This will allow for proper alignment of all bolt holes.

  1. Install the driven gear bolts (1).

Tighten

  • Tighten the bolts to 25 Nm (18 lb. ft) .
  1. Install the grommet for oil filler tube.
  2. Install the oil filler tube.
  3. Install the fuel feed line at the injection pump.
  4. Install the fuel return line to the top of the injection pump.
  5. Install all necessary harness and connectors.
  6. Install the injection lines. Refer to tags on lines. Refer to Injection Lines .See: Fuel Injector Line\Service and Repair
  7. Install intake manifold. Refer to Intake Manifold Installation .
  8. Install negative battery cables.