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Fuel Injection Pump: Installation

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  1. Install fuel injection pump. Install fuel injection pump mounting bolts from front of engine front cover. See Fig 1. Reconnect fuel return line banjo bolt at junction block.
  2. Install fuel return hose and hose clamp to fuel injection pump. Install high pressure lines from injection pump to junction block.
  3. Install fuel pressure sensor connector at junction block. Replace hose to turbocharger water feed line. Install water crossover assembly. Install air intake pipe.
  4. Install NEW O-ring lubricated with clean engine oil. Install heater pipe bracket bolt. Install heater pipe to water crossover bolts.
  5. Connect engine wiring harness. Install upper radiator hose mounting bolts and brackets. Install upper radiator hose clamp. Install turbocharger cooling hose return and clamp. Install upper radiator hose at outlet pipe.
  6. Install left idler pulley and bolt. Install PCV catch tank, hose clamp and bolt to right front of engine. Install thermostat housing bracket, wiring, fuel test port and nuts. Install alternator.
  7. Install a new O-ring to oil fill tube and lubricate O-ring with clean engine oil. Install oil fill tube. Install air conditioning/power steering bracket and bolts. Install power steering pump. Install air conditioning compressor.
  8. Install positive battery cable junction box and bolt. Install serpentine belt. Install fan blade assembly. See FAN BLADE ASSEMBLY . Install upper fan shroud. See FAN SHROUD . Refill coolant. See DRAINING & REFILLING COOLING SYSTEM .
  9. Install air intake duct between air cleaner and turbocharger inlet housing. Reconnect battery cables to both batteries. Replace all of the hold-down ties. Start engine and check for leaks or noises. After engine warms up, refill coolant reservoir to proper level. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS .
Fig 1: Removing & Installing Fuel Injector Pump
G00081878Courtesy of GENERAL MOTORS CORP.
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