Installation

FUEL INJECTION PUMP

INSTALLATION

1. Inspect the pump mounting surfaces at the pump and mounting flange for nicks, cuts or damage. Inspect o-ring surfaces for nicks, cuts or damage.
2. Clean the injection pump mounting flange at the gear housing. Also clean the front of the injection pump.
3. Install a new rubber o-ring at the pump mounting area.
4. Apply clean engine oil to the injection pump o-ring only.

The machined tapers on both the injection pump shaft and the injection pump gear must be absolutely dry, clean and free of any dirt or oil film. This will ensure proper gear-to-shaft tightening.

Clean the pump gear and shaft at the machined tapers with an evaporative cleaner such as brake cleaner.

KEYWAY INSTALLATION

1. The pump gear/keyway has an arrow and a 3-digit number stamped at the top edge. Position the keyway into the pump shaft with the arrow pointed to the rear of the pump. Also be sure that the 3-digit number stamped at the top of the keyway is the same 3-digit number stamped on the injection pump data plate. If the wrong keyway is installed, a diagnostic trouble code may be set.
2. Position the pump assembly to the mounting flange on the gear cover while aligning the injection pump shaft through the back of the injection pump gear. When installing the pump, the dowel on the mounting flange must align to the hole in the front of the pump.
3. After the pump is positioned flat to the mounting flange, install the four pump mounting nuts and finger tighten only. Do not attempt a final tightening at this time. Do not attempt to tighten (pull) the pump to the gear cover using the mounting nuts. Damage to the pump or gear cover may occur. The pump must be positioned flat to it's mounting flange before attempting to tighten the mounting nuts.
4. To prevent damage or cracking of components, tighten nuts/bolts in the following sequence:
a. Install the injection pump shaft washer and nut to the pump shaft. Finger tighten the nut only.
b. Position the lower pump bracket and install the 3 bolts. Finger tighten only.
c. Do a preliminary tightening of the injection pump shaft nut to 30 Nm (15 - 22 ft. lbs.) torque. This is not the final torque.
d. Tighten the 4 pump mounting nuts to 43 Nm (32 ft. lbs.) torque.
e. Tighten the 3 lower pump bracket-to-engine bolts to 24 Nm (18 ft. lbs.) torque.
f. Tighten the 2 engine bracket-to-engine bolts to 24 Nm (18 ft. lbs.) torque.
g. Do the final tightening of the injection pump shaft nut to 179 Nm (124 ft. lbs.) torque. Use a barring tool to prevent the engine from rotating when tightening the gear.
5. Install the plastic access cap to the front gear cover.
6. Using new gaskets, install the fuel return line and overflow valve to the side of the injection pump. Tighten the overflow valve to 24 Nm (18 ft. lbs.) torque.
7. Using new gaskets, install the fuel supply line to the side of the injection pump and the top of the fuel filter housing. Tighten the banjo bolts to 24 Nm (18ft. lbs.) torque.
8. Install all high-pressure fuel lines, intake air tube, accelerator pedal position sensor, air intake housing, engine oil dipstick tube, wiring clips, electrical cables at the intake heaters and engine lifting bracket.
9. Connect the 9-way electrical connector to the Fuel Pump Control Module (FPCM).
10. Connect the negative battery cables to both batteries.
11. Bleed the air from the fuel system. Refer to: Bleeding Fuel Lines.
12. Check the system for fuel or engine oil leaks.