Fuel Injection Pump: Installation

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

Install the new the fuel injection pump O-ring seal and lubricate with clean engine oil. Refer to: Specifications .

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Remove the Remover, Crankshaft Timing Pulley and the outer thumb-wheels only. Remove Special Service Tool: 303-249 Remover, Crankshaft Timing Pulley, 303-1317 Locking Tool, Fuel Injection Pump Sprocket.

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Align the sprocket key with the keyway on the fuel injection pump shaft and install the fuel injection pump, then install and tighten the fuel injection pump studbolts.
Torque: 17 lb.ft (23 Nm)

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NOTE: The fuel injection pump drive sprocket retaining bolt has LEFT hand threads.

Install and tighten the fuel injection pump drive sprocket retaining bolt. When tightening the LEFT hand threaded fuel pump drive sprocket bolt, the locking tool may rotate to its stop, carefully continue to tighten the fuel pump drive sprocket bolt until the specified torque is reached.

Torque: 55 lb.ft (75 Nm)

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Remove the studs and the inner thumb-wheels. Remove Special Service Tool: 303-1317 Locking Tool, Fuel Injection Pump Sprocket.

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Remove the Locking Tool, Fuel Injection Pump Sprocket. Remove Special Service Tool: 303-1317 Locking Tool, Fuel Injection Pump Sprocket.

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Using the special tool Remover/Installer, Engine Front Cover Inspection Plate, install the fuel injection pump drive sprocket access cover. Use Special Service Tool: 303-679A Remover/Installer, Engine Front Cover Inspection Plate.

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Install the upper RH fuel injection pump bracket and the upper RH fuel injection pump bracket tube nut finger tight at this stage.

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1. Install the lower RH fuel injection pump bracket and then install lower RH fuel injection pump bracket bolts.
2. NOTE: Make sure that a new lower RH fuel injection pump bracket bolt is installed.
  
  Install the lower RH fuel injection pump bracket bolt.
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Tighten the upper RH fuel injection pump bracket tube nut and the lower RH fuel injection pump bracket bolts in the sequence shown.
Torque: 1 : 89 lb.in (10 Nm) 2 : 17 lb.ft (23 Nm) 3 : 17 lb.ft (23 Nm) 4 : 17 lb.ft (23 Nm)

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1. Install the upper LH fuel injection pump bracket and the upper LH fuel injection pump bracket bolt.
2. NOTE: Make sure that a new upper LH fuel injection pump bracket bolt is installed.
  
  Install the upper LH fuel injection pump bracket bolt.
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Install the lower LH fuel injection pump bracket, the lower LH fuel injection pump bracket bolts and the lower LH fuel injection pump bracket tube nut finger tight at this stage.

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Tighten the fuel injection pump bracket tube nut and the fuel injection pump bracket bolts in the sequence shown.
Torque: 1: 16 lb.ft (22 Nm) 2: 89 lb.in (10 Nm) 3: 16 lb.ft (22 Nm)

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Attach the harness retainer to the bracket.

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1. Install and tighten the thermostat housing bracket bolt.
  Torque: 17 lb.ft (23 Nm)
2. Install and tighten the thermostat housing bracket nut.
  Torque: 89 lb.in (10 Nm)
- Connect the coolant hose and position the clamp. Use the General Equipment: Hose Clamp Remover/Installer
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Install the Coolant Pump. Refer to: Coolant Pump .
Install the cooling fan. Refer to: Cooling Fan .
Connect the fuel injection pump temperature sensor and the fuel injection pump fuel metering valve electrical connectors.
Install the intake manifold. Refer to: Intake Manifold .

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Install the fuel rail supply tube. Refer to: Fuel Rail Supply Tube .