Removal Procedure

WARNING: This page is about a different variant/trim than selected.

WARNING:

Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash.

NOTE:

Be very thorough in terms of cleanliness when working in the fuel system. Malfunctions can also occur due to very small dirt particles. Prevent dirt from entering the fuel system by cleaning the hoses and plugging the pipes and lines upon removal. Store the components so that contaminants cannot enter.

Remove the engine sight shield. Engine Sight Shield Replacement
Remove the intake manifold. Intake Manifold Replacement
Remove the engine control module bracket. Engine Control Module Bracket Replacement
Auxiliary Fluid Accumulator Replacement - Remove
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Fuel Feed Pipe (1) @ Fuel Injection Pump (2) - Disconnect - Plastic Collar Quick Connect Fitting Service
Diesel Fuel Separator (3) @ Fuel Injection Pump (2) - Disconnect - Plastic Collar Quick Connect Fitting Service
Close all open connectors with suitable closure plug.
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Disconnect the electrical connector. (1)
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Charge Air Bypass Regulator Solenoid Valve Inlet Tube (2) @ Exhaust Gas Recirculation Vacuum Regulator Solenoid Valve (1) - Disconnect
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Range Selector Lever Cable (1) @ Range Selector Lever Cable Lever - Remove - Use a suitable tool.
Range Selector Lever Cable (1) @ Transmission Range Selector Lever Cable Bracket - Remove
Push (arrows) the lashes (2) to release the range selector lever cable.
Range Selector Lever Cable (1) - Position aside
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Install the spike (1) to the EN-50885-1 remover (2).
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EN-50885-1 remover (3) - Install
Press the spike (2) into the fuel injection pump sprocket access hole plug (1).
Turn the spike 90 degrees to clamp it with the fuel injection pump sprocket access hole plug.
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Remove the fuel injection pump sprocket access hole plug by pulling strong at the handle (1) of the EN-50885-1 remover (2).
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Remove the spike (1) from the EN-50885-1 remover (2).
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Remove and DISCARD the fuel injection pump sprocket access hole plug (1) from the EN-50885-1 remover (2).
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EN-50885-2 fixing tool (3) - Install
1. Install the housing (5) to the fuel injection pump driven sprocket. Ensure that the 3 tappets (2) mesh with the 3 slots of the fuel injection pump driven sprocket (1).
2. Position the ring (4) for a good handling.
3. Screw the fixing tool (3) into the fuel injection pump driven sprocket.
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Install a 1/2 inch-extension (1) to the EN-50885-2 fixing tool (2) to counterhold.
Fuel Injection Pump Drive Pulley Nut - Loosen
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Fuel Injection Pump Drive Pulley Nut (1) - Remove
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Fuel Injection Pump Bolt (1) - Remove [2x]
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Install the pressure spindle (2) to the EN-50885-2 fixing tool (1).
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CAUTION:
DO NOT press out the fuel injection pump with the pressure spindle. Doing so can result in damage to the fuel injection pump driven sprocket.

Loosen the fuel injection fuel pump sprocket, by screwing in the pressure spindle with a hexagon socket wrench (3) into the EN-50885-2 fixing tool (1) until the fuel injection pump sprocket is disengaged.
Fuel Injection Pump (2) - Remove
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Remove and DISCARD the fuel injection pump seal ring (1) from the fuel injection pump sealing groove (2).