Removal

FUEL INJECTION PUMP

New or remanufactured fuel injection pumps should have a new overflow valve temporarily installed into side of pump. Do not install a used overflow valve into a new or remanufactured injection pump.

CAUTION: Whenever the fuel injection pump is removed from the engine, the pump drive gear is laying loose on the camshaft drive gear. Never attempt to crank or rotate the engine with the pump removed from the engine. Serious damage will occur.

REMOVAL

1. Disconnect the negative battery cables at both batteries. Cover and isolate the ends of the cables.
2. Thoroughly clean the fuel lines at the cylinder head and injection pump ends. Thoroughly clean the fuel injection pump and supply/return lines at the side of the pump.
3. Disconnect the 9-way electrical connector at the Fuel Pump Control Module (FPCM)
4. Remove the fuel return line at the side of the injection pump by removing the overflow valve. Place a rag beneath the overflow valve to catch any excess fuel.
5. Remove the fuel supply line at the side of the injection pump by removing the banjo bolt. Also remove the same line at the top of the fuel filter housing (banjo bolt).
6. Remove all high-pressure fuel lines, intake air tube, accelerator pedal position sensor, air intake housing, engine oil dipstick tube, wiring clips and electrical cables at the intake heaters and engine lifting bracket.
7. Unscrew the plastic access cap at the front gear cover.

CAUTION: To prevent the pump/gear keyway from falling into the gear housing, the engine must be rotated until the keyway is at the 12 o'clock position. If the gear retainer nut, washer or key drops into the gear housing, the cover may have to be removed to retrieve them before the engine is started.

8. Remove the nut and the washer retaining the injection pump gear to the injection pump shaft.
9. The engine can be rotated with a barring tool such as Snap-On No. SP371, MTE No. 3377371 (Cummins Tool Division), or equivalent.
10. Insert the barring tool into the flywheel housing opening.
11. Rotate the engine until the keyway is at the 12 o'clock position.
12. Use a T-bar type puller to separate the injection pump from the injection pump shaft. Attach two M8 X 1.24 (metric) screws through the puller and into the two threaded holes supplied in the pump gear. Pull the injection pump gear forward until it loosens from the injection pump shaft. Pull on the gear only enough to loosen it from the injection pump shaft. Pulling the gear too far may cause damage or breakage to the gear cover.
13. Remove the 3 lower pump bracket bolts and remove the pump bracket. Loosen, but do not remove the 2 engine bracket bolts.
14. Remove the 4 injection pump-to-gear housing mounting nuts.
15. Remove the injection pump from the gear housing. Take care not to nick the injection pump shaft on the aluminum gear housing when removing the pump. Also be very careful not to drop the pump keyway into the gear housing.

CAUTION: Whenever the fuel injection pump is removed from the engine, the pump drive gear is laying loose on the camshaft drive gear. Never attempt to crank or rotate the engine with the pump removed from the engine. Serious damage will occur.