Diesel MFI Pump: Service and Repair

FUEL INJECTION PUMP REPLACEMENT

REMOVAL PROCEDURE




1. Remove the engine cover.
2. Disconnect negative battery cable.
3. Drain the cooling system. Refer to Draining and Filling Cooling System (Static Fill) Draining and Filling Cooling System (Vac N Fill). Service and Repair
4. Remove the thermostat housing crossover.




5. Remove the center intake manifold.




6. Reposition the injection pump hose clamps at the fuel line.
7. Remove the hoses from fuel lines.




8. Remove the fuel injection pump bolts.

IMPORTANT: Be careful not to damage any mating surfaces.

9. Remove the fuel injection pump from the block. Use 2 screwdrivers to work the pump from the block towards the rear of engine keeping the pump straight.
10. The fuel injection pump may need to be rotated in order to remove it from the vehicle.

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.

NOTE: Refer to Fastener Notice.

8. Install the 3 bolts and spacers.

Tighten the bolts to 20 N.m (15 lb ft).

9. Install the gear and nut.

Tighten nut to 70 N.m (52 lb ft).

INSTALLATION PROCEDURE




1. Install the fuel injection pump to the block.
2. Install the fuel injection pump bolts.

Tighten the bolts to 21 N.m (15 lb ft).




3. Install the hoses to fuel lines.
4. Position the injection pump hose clamps at the fuel line.
5. Install the center intake manifold.




6. Install the inlet pipe.
7. Connect the fuel rail inlet pipe to the injection pump and rail.

Tighten the fittings to 41 N.m (30 lb ft).




8. Install the thermostat housing crossover.




9. Fill the cooling system. Refer to Draining and Filling Cooling System (Static Fill) Draining and Filling Cooling System (Vac N Fill). Service and Repair
10. Install the air cleaner outlet duct.
11. Connect negative battery cable.
12. Prime the fuel system. Refer to Fuel System Priming.
13. Start the engine. If the engine stalls, repeat the above step.
14. Once the engine starts, inspect for fuel leaks.
15. Install the engine cover.