Injection Pump Replacement

Caution: Never engage the starter motor to rotate the engine when the injection pump is removed as severe engine damage will occur.

Tools Required: J29664-1 Protective Covers

REMOVE OR DISCONNECT:
1. Negative battery cables.
2. Intake manifold.
3. Injection lines.

Accelerator Linkage:

4. Accelerator cable at the injection pump.
5. Detent cable (if equipped).
6. Fuel return line at the top of the injection pump.
7. Fuel inlet line from the injection pump.
8. All necessary wires and hoses from the injection pump.
9. air conditioning hose retainer bracket (if equipped).
10. Oil fill tube (includes CDR valve vent hose).
11. Grommet.
^ Scribe or paint a mark on the front cover and the injection pump flange.

Pump Drive Gear Bolts:

^ Rotate the engine to gain access to the bolts that hold the driven gear to the injection pump. Access is gained through the oil filler neck hole.
12. Bolts
13. Nuts
14. Pump
^ Cap all open lines and nozzles
15. Gasket

INSTALL OR CONNECT:
1. New gasket

Injection Pump Locating Pin:

Timing Alignment Marks:

2. Injection pump to front cover.
^ Align the locating pin on the pump hub with the slot in the injection pump driven gear.
^ Align the timing marks.

Injection Pump Installation:

3. Install and tighten nuts to 40 Nm (30 ft lbs).
^ Check the timing mark alignment before fully torquing the nuts.

4. Tighten drive gear to injection pump bolts to 25 Nm (20 ft lbs).
5. Grommet.
6. Oil fill tube including the CDR valve vent hose.
7. Air conditioning hose retainer bracket (if equipped).
8. Tighten fuel feed line at the injection pump to 25 Nm (20 ft lbs).
9. Fuel return line to the top of the injection pump.
10. Detent cable (if equipped).
11. All necessary wires and hoses.
12. Accelerator cable.
13. Injection lines.
14. Intake manifold.
15. Negative battery cables.