1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
{tag}642899179@
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
{tag}642819341@
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
{tag}642819341@
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
{tag}642893298@
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
{tag}642883508@
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
{tag}642877631@
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
{tag}642823818@
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
{tag}642813226@
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
20.Check and adjust injection pump timing. REMOVAL
1.Clean exterior of engine with solvent before removing any fuel lines to prevent entry of dirt into engine.
CAUTION: Do not wash or steam clean engine while engine is running or still hot from running. Serious damage to injection pump could occur.
2.Disconnect battery ground cables from both batteries.
Cover Plate
3.Remove adapter housing cover plate by removing two retaining bolts.
Mounting Bolts
4.Remove bolts attaching injection pump to drive gear.
5.Disconnect electrical connectors to injection pump.
Injection Pump
6.Remove fast idle solenoid bracket assembly to provide access to injection pump mounting nuts.
7.Disconnect accelerator cable and speed control cable from throttle lever.
8.Remove air cleaner assembly and duct.
9.Remove accelerator cable bracket (with cables attached) from intake manifold and position out of the way.
NOTE: All fuel lines and fittings must be capped using fuel system protector cap set T83T-9395-A to prevent fuel contamination.
10.Disconnect fuel inlet line and return line from the fuel filter.
Fuel Return Line
11.Remove fuel return hose and clip from the 90° elbow at the governor cover. Cap opening at governor cover elbow.
12.Remove fuel filter-to-injection pump fuel line and cap fittings.
NOTE: It is not necessary to remove injection lines from injection pump to remove injection pump. If lines are to be removed, loosen injection line fittings at injection pump before removing it from engine.
13.Remove fuel injection lines from nozzles and cap lines and nozzles.
14.Remove three nuts attaching injection pump to injection pump drive gear cover using injection pump mounting wrench T86T-9000-B.
15.Loosen injection line retaining clips. Remove injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time with fuel system protector cap set.
Injection Pump
16.If injection pump is to be replaced, loosen injection line retaining clips and injection nozzle fuel lines with fuel line nut wrench T83T-9396-A. Cap all fittings at this time. Do not install injection nozzle fuel lines until new pump is installed on engine.
CAUTION: Do not carry injection pump by injection nozzle fuel lines as this could cause lines to bend or crimp.
Injection Pump
17.Lift injection pump up and out of intake manifold valley and remove assembly from vehicle.
INSTALLATION
1.Install new o-ring onto drive gear end of injection pump.
2.Move injection pump down and into position on engine.
3.Position alignment dowel on injection pump into alignment hole on drive gear. If necessary, rotate pump drive shaft to align drive slot prior to installation.
Mounting Bolts
4.Install bolts attaching injection pump to drive gear and tighten to 34 Nm (25 ft lb).
Injection Pump
5.Install nuts attaching injection pump to adapter. Align scribe lines on injection pump flange and injection pump adapter. Tighten nuts to 35 Nm (26 ft lb) using injection pump mount wrench T86T-9000-B.
6.If injection nozzle fuel lines were removed from injection pump, install using fuel line nut wrench T83T-9396-A and tighten to 30 Nm (22 ft lb).
7.Remove caps from nozzles and fuel lines. Install fuel line nuts onto nozzles and tighten to 30 Nm (22 ft lb) using fuel line nut wrench T83T-9396-A.
8.Remove caps and connect fuel filter-to-injection pump fuel line.
9.Install fuel filter return and inlet fuel lines.
10.Install accelerator cable bracket to intake manifold and tighten to 16-23 Nm (12-17 ft lb).
11.Install air cleaner assembly and duct.
12.Connect accelerator and speed control cables to throttle lever.
13.Install fast idle solenoid and bracket assembly.
14.Install electrical connectors on injection pump.
NOTE: When applying silicone rubber sealant always use the bead size specified and join the components within 15 minutes of application. After 15 minutes the sealant begins to set-up and sealing effectiveness may be reduced.
16.Apply a 3.2mm (1/8-inch) bead of silicone rubber sealant D6AZ-19562-BA (ESB-M4G92-A) or equivalent in adapter housing grooves and install cover plate.
17.Connect ground cables to both batteries.
WARNING: KEEP EYES AND HANDS AWAY FROM FUEL SPRAY. FUEL SPRAYING FROM PARTIALLY OPENED CONNECTION UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.
18.Run engine and check for fuel leaks.
19.Purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until fuel flows from connection free of air bubbles.
Heleodoro Rodriguez: como puedo detertar un corto ECM y ECU
Алексей: Здравствуйте, я планирую произвести свап двигателя с 1.6 BAD на 1.8T AGU, но я хочу последний собрать на ЭБУ о AUQ. Не могу никак найти схемы двигателей AUQ и AGU для сравнения. можете как то помочь мне?
Juan carlos: muy buena ayuda mucho
Arroas: Thank you
Rubén Darío de Jesús cedano : Gracias por el aporte
hsn1987iraq@yahoo.com: yos
Ricsko: Thank you!!! :)
juck: hizit
Rubén Darío de Jesús cedano : Bueno
Rubén Darío de Jesús cedano : Thank you
Rubén Darío de Jesús cedano : Thank you very much
Maikel: vielen dank für die geile seite
diego vasquez: como acceder alldata en linea
jimmy: COMO PUEDO ACSEDER A ALLDATA EN LÍNEA
ronald alberto rivas pino: tendra informacion sobre renaut , modelo scenic megane kangoo motor 1.6 16v k4m
ronald alberto rivas pino: Esto es lo maximo lo felicito por este aporte
Matias: hola podran agregar VW GOL CLI 1995 1600cc monopunto naafta motor UNC por favor muchas graacias
Jose Luis: porque no aparece la marca Fiat
Jose Gregorio Linares Maldonado: SALUDOS DESDE ESPAÑA,ESTA PLATAFORMA SIRVE PARA EL MERCADO EUROPEP.GRACIAS
daniel: te puedes ayudar con una punta de prueba la idea es que la camioneta la dejes como si estuvieras siempre en parking o neutro
daniel: rodolfo yo por ejemplo elimine el ramal y lo que hice fue pegar 2
Rodolfo: que puedo hacer para que el circuito de encendido funcione si lo cambie de automático a mecanico
StaticX: Будет ли поддержка грузового транспорта, в частности марка DAF?
juan : hola buenas noches
silvio buitrago: exelente de mucha ayuda mucccchas gracias
freddy: necesito el diagrama electrico del Opel Astra G 2002 Z18XE, gracias.
Brayan Rolando Conejo Solis: saludos desde costa rica
Tilek: eee
Radhames: Tienen manuales para Mitsubishi L200, 2008, Diesel.?
francisco: Hello
gabriel: muy bien por la pagina
Malathion: You could include Toyota GSIC.
Абросимов Константин: Lincoln navigator 2007?
Cristian: 100 eres un crak
Леонид: Схема Audi 100 c4 2.6 ABC
Lester Eleazar Rostrán Vásquez: Tenes el diagrama de Abs con los conectores??
Lester Eleazar Rostrán Vásquez: Tenes el diagrama de Abs con los conectores??
Information for the copyright holder
Сайт kolhosniki.ru (далее — «Сайт») является общедоступным ресурсом для пользователей сети Интернет. В том случае, если Вы являетесь правообладателем материалов, размещенных на сайте, и ваши права нарушаются тем или иным образом с использованием нашего ресурса, просим незамедлительно сообщить об этом администрации сайта с помощью формы для обратной связи (внизу этой страницы).
Ваше сообщение будет незамедлительно рассмотрено и случае подтверждения, контент, нарушающий Ваши авторские права будет удален.
В соответствии с ФЕДЕРАЛЬНЫМ ЗАКОНОМ «ОБ ИНФОРМАЦИИ, ИНФОРМАЦИОННЫХ ТЕХНОЛОГИЯХ И О ЗАЩИТЕ ИНФОРМАЦИИ»
Статья 15.7. Внесудебные меры по прекращению нарушения авторских и (или) смежных прав в информационно-телекоммуникационных сетях, в том числе в сети «Интернет», принимаемые по заявлению правообладателя
Правообладатель в случае обнаружения в информационно-телекоммуникационных сетях, в том числе в сети «Интернет», сайта в сети «Интернет», на котором без его разрешения или иного законного основания размещена информация, содержащая объекты авторских и (или) смежных прав, или информация, необходимая для их получения с использованием информационно-телекоммуникационных сетей, в том числе сети «Интернет», вправе направить владельцу сайта в сети «Интернет» в письменной или электронной форме заявление о нарушении авторских и (или) смежных прав (далее — заявление). Заявление может быть направлено лицом, уполномоченным правообладателем в соответствии с законодательством Российской Федерации.
Заявление должно содержать:
сведения о правообладателе или лице, уполномоченном правообладателем (если заявление направляется таким лицом) (далее — заявитель):
а) для физического лица — фамилию, имя, отчество, паспортные данные (серия и номер, кем выдан, дата выдачи), контактную информацию (номера телефона и (или) факса, адрес электронной почты);
б) для юридического лица — наименование, место нахождения и адрес, контактную информацию (номера телефона и (или) факса, адрес электронной почты);
информацию об объекте авторских и (или) смежных прав, размещенном на сайте в сети «Интернет» без разрешения правообладателя или иного законного основания;
указание на доменное имя и (или) сетевой адрес сайта в сети «Интернет», на котором без разрешения правообладателя или иного законного основания размещена информация, содержащая объект авторских и (или) смежных прав, или информация, необходимая для его получения с использованием информационно-телекоммуникационных сетей, в том числе сети «Интернет»;
указание на наличие у правообладателя прав на объект авторских и (или) смежных прав, размещенный на сайте в сети «Интернет» без разрешения правообладателя или иного законного основания;
указание на отсутствие разрешения правообладателя на размещение на сайте в сети «Интернет» информации, содержащей объект авторских и (или) смежных прав, или информации, необходимой для его получения с использованием информационно-телекоммуникационных сетей, в том числе сети «Интернет»;
согласие заявителя на обработку его персональных данных (для заявителя — физического лица).
В случае, если заявление подается уполномоченным лицом, к заявлению прикладывается копия документа (в письменной или электронной форме), подтверждающего его полномочия.
В случае обнаружения неполноты сведений, неточностей или ошибок в заявлении владелец сайта в сети «Интернет» вправе направить заявителю в течение двадцати четырех часов с момента получения заявления уведомление об уточнении представленных сведений. Указанное уведомление может быть направлено заявителю однократно.
В течение двадцати четырех часов с момента получения уведомления, указанного в части 4 настоящей статьи, заявитель принимает меры, направленные на восполнение недостающих сведений, устранение неточностей и ошибок, и направляет владельцу сайта в сети «Интернет» уточненные сведения.
В течение сорока восьми часов с момента получения заявления или уточненных заявителем сведений (в случае направления заявителю уведомления, указанного в части 4 настоящей статьи) владелец сайта в сети «Интернет» удаляет указанную в части 1 настоящей статьи информацию.
При наличии у владельца сайта в сети «Интернет» доказательств, подтверждающих правомерность размещения на принадлежащем ему сайте в сети «Интернет» информации, содержащей объект авторских и (или) смежных прав, или информации, необходимой для его получения с использованием информационно-телекоммуникационных сетей, в том числе сети «Интернет», владелец сайта в сети «Интернет» вправе не принимать предусмотренные частью 6 настоящей статьи меры и обязан направить заявителю соответствующее уведомление с приложением указанных доказательств.
Правила настоящей статьи в равной степени распространяются на правообладателя и на лицензиата, получившего исключительную лицензию на объект авторских и (или) смежных прав.»