Fuel Injection Pump Replacement

Fuel Injection Pump Replacement

Removal Procedure

1. / Tilt the cab.
2. / Remove the engine control module (ECM) with bracket keeping the ECM connected.
3. / Turn the crankshaft to position the Number 1 cylinder at top dead center.

4. / Disconnect the electrical connector at the fuel temperature sensor (3).
5. / Disconnect the electrical connector at the suction control valve (7).
6. / Remove the fuel suction pipe (1) from the fuel supply pump (5).
7. / Remove the fuel filter leak off pipe (2) from the supply pump (5).
8. / Remove the fuel rail pipe from the supply pump (5).

9. / Remove the bracket nuts (9) and bolts (5).
10. / Remove the fuel supply pump (1) with the bracket (2) from the engine.
11. / If required, remove the gear nut (4), the gear (3) and the key from the fuel supply pump shaft.

12. / If required, remove the bracket (1) and O-ring (2) from the fuel supply pump (3).

Installation Procedure

1. / Ensure that cylinder Number 1 is at top dead center.

2. / If required, install the NEW O-ring (2) and the bracket (1) to the fuel supply pump (3) with 3 bolts (4).

Tighten
Tighten the fuel supply pump bracket bolts to 19 N·m (14 lb ft).

3. / Paint the gear teeth directly above the punch mark.
4. / Attach the key to the fuel supply pump shaft.

5. / Install the gear (3) and nut (4).

Tighten
Tighten the gear nut to 64 N·m (47 lb ft).

6. / Align the fuel supply pump bracket mark (1) and the gear punch mark (2).

7. / Fit the gasket (6) to the fuel supply pump bracket (2).
8. / Install the fuel supply pump (1) to the cylinder block.
9. / Tighten the fuel supply pump nuts (9) and bolt (5).

Tighten

• / Tighten the nuts (9) to 50 N·m (37 lb ft).
• / Tighten the bolt (5) to 76 N·m (56 lb ft).
10. / Ensure that cylinder Number 1 is at top dead center.

11. / Inspect the gear position through the inspection hole at the top of the housing. The painted portion (1) of the gear (2) must be visible through the hole. If it is not, the pump is incorrectly installed. Repeat the installation procedure.

12. / Install the fuel rail pipe to the fuel supply pump (5).

Tighten
Tighten the fuel common rail pipe nut to 44 N·m (32 lb ft).

13. / Install the fuel filter leak off pipe (2) to the fuel supply pump (5).
14. / Install the fuel suction pipe (1) to the fuel supply pump (5).
15. / Connect the fuel temperature sensor electrical connector (3).
16. / Connect the suction control valve electrical connector (7).
17. / Install the ECM with bracket. .
18. / Bleed (prime) the fuel system and inspect for leaks. .
19. / Lower the cab.