LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 125 (Engine Controls - Removal, Overhaul & Installation - 6.5L Diesel) >> Fuel Systems >> Injection Pump >> Removal & Installation

Removal & Installation

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2002 GMC Savana Special, 2002 GMC Savana Camper Special, 2002 GMC Savana, 2002 GMC C3500 HD, and 2002 Chevrolet RV Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect negative battery cables. On vans, remove engine cover. See ENGINE COVER . On all models, remove the intake manifold. See LOWER INTAKE MANIFOLD . Disconnect the injection lines. See FUEL INJECTION LINES .
  2. Disconnect the fuel inlet line from the injection pump. Disconnect all of the necessary harness connectors and the hoses from the injection pump. Disconnect the fuel return line at the top of the injection pump. Disconnect the oil fill tube. Remove the grommet from the oil filler tube. Manually rotate the engine in order to gain access to the bolts that hold the driven gear to the injection pump. The access is gained through the oil filler neck hole. Remove the driven gear bolts. Remove the injection pump flange nuts, using Injection Pump Wrench (J 41711). Remove the injection pump. Cap all of the open lines and nozzles. Remove the flange gasket. See Fig 1.
  3. Install the new flange gasket on the injection pump. Ensure that the locating stud on the injection pump hub goes into the slotted/elongated hole in the driven gear. Adjust the locating stud to the proper position in order to match with the slotted/elongated hole in the driven gear. Install the injection pump, making sure the locating stud is positioned within the slotted/elongated hole in the driven gear. Install the injection pump flange nuts.
    4. NOTE: None of the driven gear bolts should be torqued until all of the bolts are installed. This will allow for proper alignment of all of the bolt holes.
  4. Install the driven gear bolts. To complete installation, reverse removal procedure. Tighten fasteners properly. See TORQUE SPECIFICATIONS . Adjust the injection timing. See INJECTION PUMP TIMING . Ensure that the PCM electrical harness is properly routed to avoid contact with the engine cover during installation.
Fig 1: Identifying Diesel Injection Pump Components
G94H65596Courtesy of GENERAL MOTORS CORP.
scientia non olet · About LEMON Manuals