B. Replace Diesel Fuel Transfer Pump

1. Disconnect the negative battery cable from both batteries.

NOTE:
To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure.

2. Raise the vehicle on an appropriate hoist.





3. Pull back the protective rubber boot from the positive battery cable at the starter motor solenoid connection and disconnect the cable from the stud on the solenoid (Figure 2).

4. Disconnect the solenoid wire from the starter motor solenoid (Figure 2).

5. Support the starter motor with one hand and remove the three (3) starter motor to flywheel housing bolts (Figure 2).

6. Remove the starter motor from the engine compartment.

7. Thoroughly clean the area around the transfer pump and fuel lines of any contamination. Use a suitable drain pan to catch any excess fuel.

8. Disconnect the fuel line quick-connect fitting from the fuel supply line (rear fuel line).





9. Remove the front banjo bolt from the transfer pump (Figure 3). Remove and discard the banjo bolt sealing washers.

10. Disconnect the transfer pump electrical connector (Figure 3).

11. Disconnect the electrical connector from the transfer pump bracket.

12. Remove the six (6) transfer pump bracket bolts and then remove the pump and bracket as an assembly.

13. Remove the fuel supply line support bracket bolt from the top of the transfer pump bracket (Figure 3).

14. Remove the rear banjo bolt from the transfer pump (Figure 3). Remove and discard the banjo bolt sealing washers.

15. Remove the three (3) transfer pump to bracket nuts (Figure 3).

16. Remove and discard the transfer pump (Figure 3).

17. Position the new transfer pump onto the bracket and install the retaining nuts (Figure 3). Tighten the nuts to 108 in-lbs (12 Nm).

18. Install two (2) new banjo sealing washers on the rear fuel line banjo fitting. Make sure that there is a sealing washer on each side of the fitting. Loosely connect the rear banjo fitting to the new transfer pump (Figure 3). Do NOT tighten the fitting.

19. Attach the fuel supply line support bracket to the top of the transfer pump bracket (Figure 3). Tighten the support bracket bolt to 108 in-lbs (12 Nm).

20. Tighten the rear banjo bolt to 215 in-lbs (24 Nm).

21. Install the transfer pump and bracket assembly. Tighten the six (6) bracket bolts to 108 in-lbs (12 Nm).

22. Attach the electrical connector to the transfer pump bracket.

23. Connect the transfer pump electrical connector (Figure 3).

24. Install two (2) new banjo sealing washers on the front fuel line banjo fitting. Make sure that there is a sealing washer on each side of the fitting. Connect the front banjo fitting to the new transfer pump (Figure 3). Tighten the front banjo bolt to 215 in-lbs (24 Nm).

25. Connect the fuel supply line quick connect fitting.

26. Position the starter motor in the engine compartment.

27. Support the starter motor with one hand and loosely install the three (3) starter motor bolts (Figure 2).

28. Tighten the starter motor bolts to 32 ft-lbs (43.4 Nm).

29. Connect the positive battery cable and solenoid wire to the starter motor studs. Tighten the nut for the solenoid wire to 55 in-lbs (6.2 Nm). Tighten the nut for the battery cable to 120 in-lbs (13.6 Nm).

30. Install the rubber boot over the starter motor battery cable connection.

31. Lower the vehicle.

32. Reconnect the negative battery cable on both batteries.





33. Loosen but do not remove the banjo bolt that holds the fuel supply line to the side of the fuel injection pump (Figure 4). Place a shop towel around the fitting to catch any excess fuel.

34. Turn the ignition key to the CRANK position and then quickly release to key to the ON position before the engine starts. This will activate the transfer pump for approximately 25 seconds.

35. Repeat Step 34 until fuel exits from the loose banjo fitting at the fuel injection pump.

36. Tighten the fuel supply line-to-injection pump banjo bolt to 215 in-lbs (24 Nm).

37. Start the engine and check for any fuel leaks. Repair as necessary.

NOTE:
The engine may run erratically and be very noisy for a few minutes. This is a normal condition.