Fuel Injection Pump
Fuel Injection Pump
Removal
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.
WARNING: Clean all fuel residue from the engine compartment. If not removed, fuel residue may ignite when the engine is returned to operation. Failure to follow this instruction may result in serious personal injury.
WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
NOTICE: Do not loosen any fittings or plugs on the fuel injection pump.
1. Release the fuel system pressure.
2. Disconnect the battery ground cable.
3. NOTE: Use care when removing the fuel injection pump noise insulator. Spreading the openings will aid in removing the fuel injection pump noise insulator and reduce the risk of damage.
4. Remove the ACL (Air Cleaner) outlet pipe.
5.
6. NOTE: To release the fuel pressure in the high-pressure fuel tube, wrap the fuel injection pump flare nut with a shop towel to absorb any residual fuel pressure during the loosening of the fuel injection pump flare nut.
NOTE: Make sure that a new high pressure fuel tube is installed.
7.
8. NOTE: Make sure that new fuel injection pump bolts are installed.
Alternately loosen the 2 fuel injection pump bolts one complete revolution at a time.
9.
Installation
1. NOTE: The cam lobe for the fuel injection pump must be at Bottom Dead Center (BDC) for the fuel injection pump installation.
2. Inspect the fuel injection pump tappet. For additional information, refer to Fuel Injection Pump Tappet Inspection Procedures.
3.
4. NOTICE: Only rotate the crankshaft clockwise or damage to the engine may occur.
5. NOTE: Apply clean engine oil to the fuel injection pump tappet and to the fuel injection pump cover bore.
6. NOTE: Make sure that a new fuel injection pump O-ring seal is installed.
NOTE: Apply clean engine oil to the fuel injection pump O-ring seal.
Lubricate and install a new fuel injection pump O-ring seal onto the fuel injection pump.
7. NOTE: Make sure that new fuel injection pump bolts are installed.
Install the fuel injection pump and loosely install 2 new fuel injection pump bolts, alternately tighten each bolt one complete revolution until seated. Tighten the 2 fuel injection pump bolts in the following 2 stages.
- Stage 1: Tighten each bolt to 5 Nm (44 lb-in).
- Stage 2: Tighten each bolt an additional 55 degrees.
8. Tighten to 17 Nm (150 lb-in).
9.
10. NOTE: Make sure that a new high pressure fuel tube is installed.
- Hand tighten the high pressure fuel tube-to-fuel rail flare nut.
- Hand tighten the high pressure fuel tube-to-fuel injection pump flare nut.
11. Loosely install the 2 high pressure fuel tube bracket bolts.
12. Tighten the 2 high pressure fuel tube flare nuts in the following 2 stages.
NOTE: Calculate the correct torque wrench setting for the following torque.
- Stage 1: Using a torque adapter, tighten to 15 Nm (133 lb-in).
- Stage 2: Tighten an additional 30 degrees.
13. Tighten to 10 Nm (89 lb-in).
14. For more information, refer to Fuel Delivery and Air Induction
15. NOTE: Use care when installing the fuel injection pump noise insulator. Spreading the openings will aid in installing the fuel injection pump noise insulator and reduce the risk of damage.
16. Connect the battery ground cable.
17. Pressurize the fuel system,
18. Install the ACL (Air Cleaner) outlet pipe.