| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Part Name | Qty |
| A
(1) |
350-7549 | Engine Turning Tool | 1 |
| B | 294-3031 | Fuel Pump Pinch Bolt | 1 |
| (1) | The tooling is designed to turn the crankshaft in engines that have limited access to the flywheel housing. The tool engages all four bolt heads which are located in the front vibration damper. |
Note: Cleanliness is a critical factor. Clean the exterior of the components before you begin the removal procedure. This action will help to prevent dirt from entering the internal mechanism.
| NOTICE |
|---|
|
Contact with high pressure fuel may cause personal injury or death. Wait 60 seconds after the engine has stopped to allow fuel pressure to purge before any service or repair is performed on the engine fuel lines. |
| NOTICE |
|---|
|
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. |
| NOTICE |
|---|
|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
 |
|
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death. |
- Ensure that the No. 1 cylinder is at top center compression stroke. Refer to "Testing and Adjusting", Finding Top Center Position for No. 1 Piston.
- Remove all necessary components to access the fuel injection pump.
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Illustration 1 g02351981 - Remove plug (1) and remove O-ring seal (2).
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Illustration 2 g06163397 - Using Tooling (A) and a 3/4" ratchet, rotate the crankshaft until the timing mark on the fuel pump is visible through the inspection hole. Install Tooling (B) and tighten to a torque of
9 ± 1 N·m (80 ± 9 lb in) .Note: Mark the damper in relation to the front timing cover as a visual reference to ensure that the crankshaft has not moved while the fuel injection pump is removed.
Note: The pump will not function while Tooling (B) is installed. Running the fuel injection pump with the tooling installed will result in pump damage and system contamination.
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Illustration 3 g02025176 Note: For installation purposes, mark and note the orientation of each harness assembly (3).
- Disconnect harness assemblies (3).
- Remove nut (5) and remove the clamp assembly. Discard the clamp assembly.
- Loosen nuts (4) and (7). Remove the fuel line and discard the fuel line.
- Disconnect hose assembly (6).
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Illustration 4 g02029098 - Disconnect tube assemblies (9).
- Disconnect hose assemblies (10) and (11).
- Remove bolts (8).
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Illustration 5 g02029093 - Disconnect tube assembly (12).
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Illustration 6 g02025262 - Remove bolts (13) and remove fuel pump (14).
- Position fuel pump (14) and install bolts (13).
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Illustration 8 g02029093 - Connect tube assembly (12).
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Illustration 9 g02029098 - Install bolts (8).
- Connect tube assembly (9) and connect both hose assemblies (10) and (11).
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Illustration 10 g02025176 Note: During installation, make sure that the fuel line caps remain in position until the fuel line is positioned near the corresponding ports to prevent contamination. Ensure that the areas around the rail and fuel lines are thoroughly clean before continuing this procedure. If any parts are worn or damaged, use new parts for replacement. Cleanliness is an important factor. Ensure that no debris gets introduced into the fuel system during the installation procedure. If any parts are worn or damaged, use new parts for replacement.
- Connect harness assemblies (3).
- Install a new fuel line. Hand tighten nuts (4) and (7).
- Position the clamp assembly and install nut (5). Hand tighten the nut. Failure to place the grommet correctly on the fuel line could result in a failed fuel line.
Note: Ensure that the fuel lines are centered in the nuts prior to tightening. Do not use excessive force or bending to assemble the fuel lines.
- Tighten nut (4) at the fuel rail to a torque of
27 ± 3 N·m (239 ± 27 lb in) . - Tighten nut (7) to a torque of
27 ± 3 N·m (239 ± 27 lb in) . - Tighten nut (5) to a torque of
12 ± 3 N·m (105 ± 27 lb in) .Show/hide table
Illustration 11 g06163397 - Remove Tooling (B).
Note: The pump will not function while Tooling (B) is installed. Running the fuel injection pump with the tooling installed will result in pump damage and system contamination.
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Illustration 12 g02351981 - Install O-ring seal (2) and plug (1). Tighten the plug to a torque of
9 ± 1 N·m (80 ± 9 lb in) .
Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the components, if necessary.
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| Illustration 7 | g02025262 |