Removal

REMOVAL

CAUTION: Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only.




1. Disconnect both negative battery cables at both batteries. Cover and isolate ends of both cables.

2. Remove intake manifold air intake tube (above injection pump) and its rubber connector hose (2).

3. Remove accessory drive belt.




4. Thoroughly clean rear of injection pump, and attachment points for its fuel lines. Also clean the opposite ends of these same lines at their attachment points.

5. Disconnect quick-connect fitting by pressing on button (1).

CAUTION: Whenever a fuel line fitting is connected to a secondary fitting, always use a back-up wrench on the secondary fitting. Do not allow the secondary fitting to rotate.

6. Remove high-pressure fuel line to fuel rail.

7. Remove banjo bolt (2).

8. Disconnect FCA (Fuel Control Actuator) electrical connector (3).




9. Remove line clamp (5).




10. Remove fuel pump drive gear access cover with a 3/8 inch drive ratchet. Access cover (2) is threaded to timing gear cover.

11. Remove fuel pump drive gear mounting nut and washer.




12. Attach C3428B, or L4407A (or equivalent) gear puller (1) to pump drive gear with 2 bolts, and separate gear from pump (a keyway is not used on this particular injection pump). Leave drive gear hanging loose within timing gear cover.




13. Remove three injection pump mounting nuts (6), and remove pump from engine.