Fuel Injection Pump – Remove and install


Removal procedure

If necessary, remove the fuel filter base.
If necessary, remove the fuel priming pump. Remove the front cover.
Either Tooling can be used. Use the Tooling that is most suitable.
Isolate the fuel supply. Isolate the electrical supply.
Use Tooling in order to rotate the crankshaft so that number one piston is at top dead center on the compression stroke.
Use Tooling in order to lock the camshaft in the correct position. Use Tooling in order to lock the crankshaft in the correct position.
Remove the backlash from the fuel pump gear. Lock the fuel injection pump in the correct position and remove the fuel pump gear.


Place a suitable container below the fuel injection pump (1) in order to catch any fuel that might be spilled. Clean up any spillage of fuel immediately.


Disconnect the plastic tube assembly (2) from the fuel injection pump (1).
Disconnect the engine wiring harness (7) from the solenoid (3) of the fuel injection pump. Disconnect the engine wiring harness (7) from the position sensor (4) for the fuel injection pump. The engine wiring harness should be positioned in order to avoid an obstruction to the fuel injection pump.
Remove the plastic tube assembly (11) from the fuel transfer pump (8).
Disconnect the plastic tube assembly (10) from the outlet of the fuel transfer pump (8).
Disconnect the plastic tube assembly (5) from the fuel injection pump (1).
Remove the tube assembly (12) for the fuel return from the fuel transfer pump and the cylinder head. Disconnect the tube assembly at the fuel transfer pump first in order to drain the fuel from the cylinder head.
Remove the tube assembly (9) for the engine oil supply to the fuel injection pump (1). Plug or cap all open ports and tube assemblies immediately with new plugs or caps.
Remove the fuel injection line (6) that connects the fuel injection pump to the fuel manifold.  Use Tooling in order to plug the open ports in the fuel injection pump and in the fuel manifold. Discard the fuel injection line.


Remove the two setscrews (15). Remove the two setscrews (14) and remove the support bracket (13) from the fuel injection pump (1).
Remove the three setscrews (17) and sealing washers (18). Discard the sealing washers. The fuel injection pump should be supported by hand as the setscrews are removed.


Carefully remove the fuel injection pump (1) from the front housing (19). Ensure that the bore (20) in the front housing is not damaged as the fuel injection pump is removed. Remove the O-ring seal (21) from the fuel injection pump (1). Discard the O-ring seal.
If necessary, remove the position sensor (4) from the fuel injection pump (1).
If necessary, remove the fuel transfer pump (8) from the fuel injection pump (1).

Installation procedure

Install the fuel transfer pump (8) to the fuel injection pump (1).


Install the position sensor (4) to the fuel injection pump (1).  A new fuel injection pump assembly includes the fuel transfer pump and the position sensor.
Position Tooling onto the shaft (22) of the fuel injection pump. Align the lever of Tooling with the key slot (23). Engage the lever into the key slot.
Insert the locking pin of Tooling into the hole (24) in fuel injection pump. If the locking pin can be inserted into the hole, the fuel injection pump timing is correct. If the locking pin cannot be inserted into the hole, the fuel injection pump timing is not correct. There should be no resistance when the locking pin is inserted. If necessary, loosen the locking screw (25) on the fuel injection pump. Slide the spacer (26) into position (X). Tighten the locking screw (25) to a torque of 9 N·m (80 lb in). This will prevent the locking screw from tightening against the shaft (22). The fuel injection pump is now unlocked.
Position Tooling onto the shaft (22) of the fuel injection pump. Align the lever of Tooling with the key slot (23) in the fuel injection pump. Engage the lever into the key slot.
Use the lever of Tooling to rotate the shaft (22) until the pin of Tooling can be engaged into the hole (24). Engage the pin of Tooling into the hole.
Loosen the locking screw (25) in the fuel injection pump. Slide the spacer (26) into position (Y). Tighten the locking screw (25) against the shaft of the fuel injection pump to a torque of 9 N·m (80 lb in). The fuel injection pump is now locked. Remove tooling.

Inspect the bore (20) in the front housing (19) for damage. If the bore is damaged, replace the front housing.
Use Tooling to lubricate a new O-ring seal (21). Install the O-ring seal onto the fuel injection pump (1).
Align the holes in the fuel injection pump (1) with the holes in the front housing (19). Carefully install the fuel injection pump to the front housing. The fuel injection pump should be supported by hand until the setscrews are installed.
Install the three setscrews (17) and three new sealing washers (18). Tighten the setscrews to a torque of 25 N·m (18 lb ft).
If necessary, use Tooling in order to rotate the crankshaft so that number one piston is at top dead center on the compression stroke.
Use Tooling in order to lock the camshaft in the correct position. Use Tooling in order to lock the crankshaft in the correct position.
Install the fuel injection pump gear to the fuel injection pump. Ensure that the spacer (26) on the fuel injection pump is in the unlocked position (X) after the installation of fuel injection pump gear is completed. Install the front cover.

Position the support bracket (13) onto the fuel injection pump (1). Install the two setscrews (14) finger tight. Install the two setscrews (15) finger tight.
Tighten the setscrews (15) to a torque of 22 N·m (16 lb ft). the setscrews (14) to a torque of 22 N·m (16 lb ft). Some engines have a single M10 nut and a bolt in place of the two setscrews (15). Tighten the nut and bolt to a torque of 44 N·m (32.5 lb ft). Ensure that the fuel injection pump is not stressed as the fasteners for the bracket are tightened.

Remove the appropriate plugs and caps in order to install tube assembly (9) for the engine oil supply to the fuel injection pump. Install the tube assembly (9). Tighten the nuts at both ends of the tube assembly.
Remove the appropriate caps in order to install the fuel injection line (6). Install a new fuel injection line (6) to the fuel injection pump and to the fuel manifold.
Remove the plugs and caps from the remaining ports and tube assemblies.
Install the tube assembly (12) for the fuel return to the fuel transfer pump and to the cylinder head. Tighten the nuts at both ends of the tube assembly.
Install the plastic tube assembly (5) to the fuel injection pump (1).
Install the plastic tube assembly (10) for the fuel outlet to the fuel transfer pump (8). Install the plastic tube assembly (11) to the fuel transfer pump (8).
Connect the harness assembly (7) to the solenoid (3) on the fuel injection pump. Connect the harness assembly (7) to the position sensor (4) on the fuel injection pump. If necessary, install the fuel priming pump.
If necessary, install the fuel filter base. Restore the fuel supply.
Restore the electrical supply. Remove the air from the fuel system.