Fuel Injection Pump

Figure 3-56: Fuel Injection Pump:

Fuel Injection Pump

Removal
1. Remove engine oil filler neck and cap.
2. Disconnect intake hoses at intake manifold.
3. Disconnect fuel lines at injectors. Then remove fuel line clamps.
4. Remove clip attaching accelerator cable to pump lever.
5. Disconnect all solenoid and harness wires at injection pump.
6. Remove throttle position sensor.
7. Disconnect fuel hoses at injection pump.
8. Disconnect injector fuel lines at pump. Tag lines for assembly reference if desired.
9. Remove throttle return spring from throttle shaft lever.

NOTE: Rotate engine to gain access to driven gear-to-injection pump capscrews through oil filler tube opening

10. Remove bolts attaching pump driven gear.
11. Remove nuts and washers, attaching pump and gasket to timing gear cover.
12. Remove pump (Figure 3-56).

Service

The turbo diesel electronic injection pump is not serviceable. Only the pump solenoids, sensors, gaskets, and drive gears are serviceable. The pump should be replaced as an assembly if an internal fault occurs.

Figure 3-57: Injection Pump Removal/Installation:

Installation
1. Install gasket and fuel injection pump on timing gear cover (Figure 3-57)
2. Align pin on pump drive shaft with elongated hole in pump driven gear.
3. Align timing marks on injection pump and front cover.
4. Tighten injection pump attaching nuts.
5. Align and install pump driven gear. Tighten gear attaching bolts to 13-20 lb-ft (18-27 N.m).
6. Install hose adapter on injection pump if equipped.
7. Install accelerator cable and bracket.
8. Connect throttle return spring to throttle shaft lever and accelerator cable mounting bracket.
9. Connect fuel line to pump.
10. Install TPS.
11. Connect fuel lines to injectors.
12. Install injector line clamps and brackets.
13. Install engine oil filler tube.
14. Install fuel injector lines.
15. Install fast idle solenoid and mounting bracket, if equipped.
16. Adjust accelerator linkage on NA diesel models.
17. Connect fuel return hose.
18. Connect solenoid and sensor wires.
19. Reprogram TDC offset.