Fuel Transfer Pump – Remove and install


Removal procedure

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


Remove the plastic tube assembly (2) from the fuel transfer pump (1).
Disconnect the plastic tube assembly (3) from the outlet of the fuel transfer pump (1).
Remove the connector (4) from the fuel transfer pump (1). Remove the O-ring seal (not shown) from the connector (4). Discard the O-ring seal. If necessary, remove the connector (7) from the fuel transfer pump (1). Remove the O-ring seal from the connector (7). Discard the O-ring seal.

Remove the tube assembly (6) 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 (5) for the engine oil supply from the fuel injection pump (8). Plug or cap all open ports and tube assemblies immediately with new plugs or caps.
Use an allen wrench with a ball end in order to remove the five allen head screws (9) that secure the fuel transfer pump to the fuel injection pump (8).


Remove fuel transfer pump (1) from the fuel injection pump (8). Do not remove the dowels (10) from the fuel injection pump.


Remove the O-ring seal (11) from the fuel transfer pump (1). Discard the O-ring seal.

Installation procedure

Ensure that the mating faces of the fuel injection pump (8) and the fuel transfer pump (1) are clean and free from damage.
Install a new O-ring seal (11) to fuel transfer pump (1). Lubricate the O-ring seal with clean engine oil.
Align the holes in the fuel transfer pump (1) with the dowels (10) in the fuel injection pump (8). Install the fuel transfer pump to the fuel injection pump.

Use an allen wrench with a ball end to install the five allen head screws (9). Tighten the allen head screws to a torque of 30 N·m (22 lb ft).
Remove the plugs and the caps from the ports and tube assemblies.
Install the tube assembly (5) for the engine oil supply to the fuel injection pump (8) and to the cylinder block.
Install the tube assembly (6) for the fuel return to the fuel transfer pump (1) and to the cylinder head.
Install a new O-ring seal (not shown) to the connector (4). Install the connector (4) to the fuel transfer pump (1). 

Tighten the connector to torque of 15 N·m (11 lb ft).
If necessary, install a new O-ring seal (not shown) to the connector (7) and install the connector (7) to the fuel transfer pump (1). Tighten the connector to torque of 15 N·m (11 lb ft). Connect the plastic tube assembly (3) to the outlet of the fuel transfer pump (1).
Install the plastic tube assembly (2) to the fuel transfer pump (1).
Restore the fuel supply. Remove the air from the fuel system.