Fuel Injection Pump: Installation

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

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NOTE: While mounting the pump to the engine, the pump flange must be inserted parallel and without tilting into the pivot.

Install the fuel injection pump, then install and tighten the fuel injection pump spacers.

Torque: 18 lb.ft (24 Nm)

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Connect the electrical connector.

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Install the fuel rail supply tube bracket, then install and tighten the fuel rail supply tube bracket bolts.
Torque: 89 lb.in (10 Nm)

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NOTE: The crankshaft gear contains a single timing mark. The camshaft drive gear contains a single timing mark and a double timing mark. The fuel injection pump drive gear contains a double timing mark. The engine is timed correctly when the single timing mark on the crankshaft drive gear is aligned with the double timing mark on the camshaft gear, and the single timing mark on the camshaft drive gear is aligned with the double timing mark on the fuel injection pump drive gear. Additionally, the keyway on the fuel injection pump drive gear must be at 12 o'clock position.

NOTE: Ensure that the fuel injection pump shaft pin is in a vertical position.

NOTE: Align the keyway on the fuel injection pump drive gear with the pin on the fuel injection pump shaft.

NOTE: A replacement fuel injection pump drive gear may be thinner than the original gear.
1. Install the fuel injection pump drive gear, make sure the single timing mark on the camshaft drive gear is aligned correctly with the double timing mark on the fuel injection pump drive gear.
2. Install and tighten the fuel injection pump drive gear nut.
  Torque: 59 lb.ft (80 Nm)
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Install the vacuum pump and the bolts.
Torque:Stage 1: 89 lb.in (10 Nm) | Stage 2: 45 deg.

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Connect the vacuum hose.

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Install the cooling fan drive assembly. Refer to: COOLING FAN DRIVE ASSEMBLY
Install the fuel rail supply tube. Refer to: Fuel Rail Supply Tube .
NOTE: This step is required only when a new fuel injection pump is being installed.

After the new fuel injection pump is installed, using a diagnostic scan tool, perform the following:
- Reset/clear the specified function for the fuel system - high pressure side.
- Clear the continuous PCM DTC's and reset the emissions monitors information in the PCM. Refer to ENGINE CONTROLS - DIAGNOSTIC METHODS (DIESEL)