Fuel Injection Pump: Removal
WARNING: This page is about a different variant/trim than selected.
NOTE:
Do not work on the fuel system until the pressure has been released and the engine has cooled. Fuel in the high-pressure fuel system is hot and under very high pressure. High-pressure fuel may cause cuts and contact with hot fuel may cause burns. Failure to follow these instructions may result in serious personal injury.
- 1.
Remove the intake manifold. Refer to: Intake Manifold .
- 2.
Disconnect the fuel injection pump temperature sensor and the fuel injection pump fuel metering valve electrical connectors.
- 3.
Remove the Coolant Pump. Refer to: Coolant Pump .
- 4.
- 1.
Remove the thermostat housing bracket bolt.
- 2.
Remove the thermostat housing bracket nut.
- Release the clamp and remove the coolant hose. Use the General Equipment: Hose Clamp Remover/Installer
- 1.
- 5.NOTE: Use a back-up wrench on the fuel injector supply tube fittings.
Remove and discard the #2 and the #3 fuel injector supply tubes.
- 6.NOTE: Use a back-up wrench on the fuel injection pump fuel supply tube fitting.
- 1.
Remove the fuel rail supply tube mounting bolts.
- 2.
Remove and discard the fuel rail supply tube.
- 1.
- 7.
Remove the lower LH fuel injection pump bracket bolts, the lower LH fuel injection pump bracket tube nut and the lower LH fuel injection pump bracket.
- 8.
- 1.
Remove and discard the upper LH fuel injection pump bracket bolt.
- 2.
Remove the upper LH fuel injection pump bracket bolt and the upper LH fuel injection pump bracket.
- 1.
- 10.
- 1.
Remove and discard the lower RH fuel injection pump bracket bolt.
- 2.
Remove the lower RH fuel injection pump bracket bolts and then remove lower RH fuel injection pump bracket.
- 1.
- 11.
Remove the upper RH fuel injection pump bracket tube nut and the upper RH fuel injection pump bracket.
- 12.
Using the special tool Remover/Installer, Engine Front Cover Inspection Plate, remove the fuel injection pump drive sprocket access cover.Use Special Service Tool: 303-679A Remover/Installer, Engine Front Cover Inspection Plate.
- 13.NOTE: Only rotate the crankshaft Clockwise (CW) or damage to the engine may occur.
- 1.
Install the Locking Tool, Fuel Injection Pump Sprocket, rotate all the way to the right.Install Special Service Tool: 303-1317 Locking Tool, Fuel Injection Pump Sprocket.
- 2.
Rotate the crankshaft Clockwise (CW) as needed.
- 3.
Align the threaded holes in the fuel injection pump drive sprocket with the smaller holes in the Locking Tool, Fuel Injection Pump Sprocket.
- 1.
- 14.NOTE: The inner thumb-wheels are fixed to the studs and do not turn.
Install the studs and the inner thumb-wheels finger tight.
Install Special Service Tool: 303-1317 Locking Tool, Fuel Injection Pump Sprocket.
- 15.NOTE: The fuel injection pump drive sprocket retaining bolt has LEFT hand threads.
Remove the fuel injection pump drive sprocket retaining bolt.
- 16.NOTE: Special tool 303-249-01 tool has left hand threads.
Install the adapter. Install Special Service Tool: 303-249-01 Adapter for 303-249.
- 18.
Install the Remover, Crankshaft Timing Pulley and the outer thumb-wheels. Using the special tool press the fuel injection pump from the fuel injection pump drive sprocket.Install Special Service Tool: 303-1317 Locking Tool, Fuel Injection Pump Sprocket., 303-249 Remover, Crankshaft Timing Pulley.
- 20.NOTE: Special tool 303-249-01 tool has left hand threads.
Remove the adapter.
Remove Special Service Tool: 303-249-01 Adapter for 303-249.