Injection Pump Replace

Fig. 23 Injection Pump Cylinder Numbering Sequence:

Prior to removing any fuel lines, clean the exterior of lines with clean fuel oil or solvent to prevent contamination.
1. Disconnect battery ground cables.
2. On E-250---350 models, remove engine cover.
3. On all models, remove engine oil filler neck, then the injection pump to drive gear attaching bolts.
4. Disconnect electrical connectors from injection pump.
5. Disconnect accelerator cable and, if equipped, speed control cable from throttle lever.
6. Remove air cleaner and install intake opening cover, tool T83T-9424-A.
7. Remove accelerator cable bracket, with cables attached, and position aside.
8. On 1985---87 E-250-350 models, disconnect fuel inlet and return lines at fuel filter, then remove fuel filter and bracket as an assembly.
9. On all models, remove fuel filter to injection pump fuel line and cap fittings.
10. Remove and cap pump inlet elbow and fitting adapter.
11. Remove fuel return line from pump and cap fittings. It is not necessary to remove injection lines when removing injection pump. If lines are to be removed, loosen line fittings at pump before removing it from engine. Fuel lines must be removed in the following sequence, Fig. 19, 5-6-4-8-3-1-7-2, and installed in reverse order.
12. Remove injection lines from nozzles. Cap lines and nozzles.
13. Remove injection pump to adapter attaching nuts.
14. Loosen injection line retaining clips and injection nozzle fuel lines and cap all fittings. Do not install injection nozzle fuel lines until pump is installed in engine.
15. Remove injection pump, with nozzle lines attached, through passenger compartment on E-250---350 models, or from engine compartment on F-250---350 models.
16. Reverse procedure to install. Note the following:
a. Install new O-rings on drive gear end of injection pump and pump fitting adapter.
b. Torque pump adapter nuts to 14 ft. lbs.
c. Torque nozzle connector nuts and pump outlet fitting nut to 22 ft. lbs.
d. Install elbow in pump adapter and torque to a minimum of 6 ft. lbs., then tighten further to align elbow with fuel inlet line, if necessary. Do not exceed one full turn or 10 ft. lbs.
e. Apply suitable pipe sealant to pump elbow threads and a 1/8 inch bead of RTV sealant to adapter housing mating surface.