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Diagnosis and repair



REMOVAL:

NOTE: Before removing any fuel lines, clean exterior of each nozzle assembly and surrounding area with solvent to prevent entry of dirt into fuel system when fuel lines are removed. Blow dry with compressed air.

1.Disconnect ground cables from both batteries.
2.Remove air cleaner and cap intake manifold opening with intake manifold cover.
3.Disconnect accelerator cable and speed control cable, if so equipped, from injection pump.
4.Remove accelerator cable bracket from intake manifold and position out of the way with cable(s) attached.
5.Disconnect fuel line from fuel filter to injection pump and cap all fittings to prevent fuel system contamination.
6.Disconnect and cap nozzle fuel lines at nozzles.
7.Remove fuel line clamps from fuel lines to be removed.
8.Remove and cap injection pump inlet elbow.
9.Remove and cap inlet fitting adapter.

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10.Remove injector nozzle lines, one at a time from injection pump using fuel line nut wrench.

NOTE: Fuel lines must be removed following this sequence: 5-6-4-8-3-1-7-2. Install caps on each end of each fuel line and pump fitting as it is removed and identify each fuel line accordingly.

INSTALLATION:
1.Install fuel lines on injection pump, using fuel line nut wrench, one at a time, and tighten to 30 Nm (22 ft lb).

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NOTE: Fuel lines must be installed in the sequence: 2-7-1-3-8-4-6-5.

2.Clean old sealant from injection pump elbow, using clean solvent, and dry thoroughly.
3.Apply a light coating of pipe sealant with Teflon(r) on elbow threads.
4.Install elbow in injection pump adapter and tighten to 8 Nm (10 ft lb). Tighten further, if necessary, to align elbow with injection pump fuel inlet line, but do not exceed 360° of rotation or 13 Nm (10 ft lb).
5.Remove caps from fuel lines and connect to nozzles. Tighten to 30 Nm (22 ft lb) using fuel line nut wrench.
6.Uncap and connect fuel line from fuel filter to injection pump and tighten to 30 Nm (22 ft lb).
7.Install fuel line retaining clamps and tighten.
8.Install accelerator cable bracket onto intake manifold and tighten to 16-23 Nm (12-17 ft lb).
9.Connect accelerator and speed control cable, if so equipped, to injection pump throttle lever.
10.Remove intake manifold cover, and install air cleaner.
11.Connect ground cables to both batteries.

NOTE: Some abnormal drive symptoms may occur on vehicles equipped with Transmission Electronic Control Assembly (TECA) when the battery has been disconnected and reconnected. The vehicle may need to be driven 10 or more miles to relearn its adaptive strategy.

12.Run engine and check for fuel leaks.

WARNING: Keep eyes and hands away from nozzle spray. Fuel spraying from the nozzle under high pressure can penetrate the skin and cause infection. Medical attention should be provided immediately in the event of skin penetration.

13.If necessary, purge high pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until bubble-free fuel flows from connection.

REMOVAL:

NOTE: Before removing any fuel lines, clean exterior of each nozzle assembly and surrounding area with solvent to prevent entry of dirt into fuel system when fuel lines are removed. Blow dry with compressed air.

1.Disconnect ground cables from both batteries.
2.Remove air cleaner and cap intake manifold opening with intake manifold cover.
3.Disconnect accelerator cable and speed control cable, if so equipped, from injection pump.
4.Remove accelerator cable bracket from intake manifold and position out of the way with cable(s) attached.
5.Disconnect fuel line from fuel filter to injection pump and cap all fittings to prevent fuel system contamination.
6.Disconnect and cap nozzle fuel lines at nozzles.
7.Remove fuel line clamps from fuel lines to be removed.
8.Remove and cap injection pump inlet elbow.
9.Remove and cap inlet fitting adapter.

Injection Pump Cylinder Number SequenceInjection Pump Cylinder Number Sequence


10.Remove injector nozzle lines, one at a time from injection pump using fuel line nut wrench.

NOTE: Fuel lines must be removed following this sequence: 5-6-4-8-3-1-7-2. Install caps on each end of each fuel line and pump fitting as it is removed and identify each fuel line accordingly.

INSTALLATION:
1.Install fuel lines on injection pump, using fuel line nut wrench, one at a time, and tighten to 30 Nm (22 ft lb).

{tag}643857426@

NOTE: Fuel lines must be installed in the sequence: 2-7-1-3-8-4-6-5.

2.Clean old sealant from injection pump elbow, using clean solvent, and dry thoroughly.
3.Apply a light coating of pipe sealant with Teflon(r) on elbow threads.
4.Install elbow in injection pump adapter and tighten to 8 Nm (10 ft lb). Tighten further, if necessary, to align elbow with injection pump fuel inlet line, but do not exceed 360° of rotation or 13 Nm (10 ft lb).
5.Remove caps from fuel lines and connect to nozzles. Tighten to 30 Nm (22 ft lb) using fuel line nut wrench.
6.Uncap and connect fuel line from fuel filter to injection pump and tighten to 30 Nm (22 ft lb).
7.Install fuel line retaining clamps and tighten.
8.Install accelerator cable bracket onto intake manifold and tighten to 16-23 Nm (12-17 ft lb).
9.Connect accelerator and speed control cable, if so equipped, to injection pump throttle lever.
10.Remove intake manifold cover, and install air cleaner.
11.Connect ground cables to both batteries.

NOTE: Some abnormal drive symptoms may occur on vehicles equipped with Transmission Electronic Control Assembly (TECA) when the battery has been disconnected and reconnected. The vehicle may need to be driven 10 or more miles to relearn its adaptive strategy.

12.Run engine and check for fuel leaks.

WARNING: Keep eyes and hands away from nozzle spray. Fuel spraying from the nozzle under high pressure can penetrate the skin and cause infection. Medical attention should be provided immediately in the event of skin penetration.

13.If necessary, purge high pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until bubble-free fuel flows from connection.

REMOVAL:

NOTE: Before removing any fuel lines, clean exterior of each nozzle assembly and surrounding area with solvent to prevent entry of dirt into fuel system when fuel lines are removed. Blow dry with compressed air.

1.Disconnect ground cables from both batteries.
2.Remove air cleaner and cap intake manifold opening with intake manifold cover.
3.Disconnect accelerator cable and speed control cable, if so equipped, from injection pump.
4.Remove accelerator cable bracket from intake manifold and position out of the way with cable(s) attached.
5.Disconnect fuel line from fuel filter to injection pump and cap all fittings to prevent fuel system contamination.
6.Disconnect and cap nozzle fuel lines at nozzles.
7.Remove fuel line clamps from fuel lines to be removed.
8.Remove and cap injection pump inlet elbow.
9.Remove and cap inlet fitting adapter.

{tag}643823026@

10.Remove injector nozzle lines, one at a time from injection pump using fuel line nut wrench.

NOTE: Fuel lines must be removed following this sequence: 5-6-4-8-3-1-7-2. Install caps on each end of each fuel line and pump fitting as it is removed and identify each fuel line accordingly.

INSTALLATION:
1.Install fuel lines on injection pump, using fuel line nut wrench, one at a time, and tighten to 30 Nm (22 ft lb).

Fuel Line RoutingFuel Line Routing


NOTE: Fuel lines must be installed in the sequence: 2-7-1-3-8-4-6-5.

2.Clean old sealant from injection pump elbow, using clean solvent, and dry thoroughly.
3.Apply a light coating of pipe sealant with Teflon(r) on elbow threads.
4.Install elbow in injection pump adapter and tighten to 8 Nm (10 ft lb). Tighten further, if necessary, to align elbow with injection pump fuel inlet line, but do not exceed 360° of rotation or 13 Nm (10 ft lb).
5.Remove caps from fuel lines and connect to nozzles. Tighten to 30 Nm (22 ft lb) using fuel line nut wrench.
6.Uncap and connect fuel line from fuel filter to injection pump and tighten to 30 Nm (22 ft lb).
7.Install fuel line retaining clamps and tighten.
8.Install accelerator cable bracket onto intake manifold and tighten to 16-23 Nm (12-17 ft lb).
9.Connect accelerator and speed control cable, if so equipped, to injection pump throttle lever.
10.Remove intake manifold cover, and install air cleaner.
11.Connect ground cables to both batteries.

NOTE: Some abnormal drive symptoms may occur on vehicles equipped with Transmission Electronic Control Assembly (TECA) when the battery has been disconnected and reconnected. The vehicle may need to be driven 10 or more miles to relearn its adaptive strategy.

12.Run engine and check for fuel leaks.

WARNING: Keep eyes and hands away from nozzle spray. Fuel spraying from the nozzle under high pressure can penetrate the skin and cause infection. Medical attention should be provided immediately in the event of skin penetration.

13.If necessary, purge high pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until bubble-free fuel flows from connection.

REMOVAL:

NOTE: Before removing any fuel lines, clean exterior of each nozzle assembly and surrounding area with solvent to prevent entry of dirt into fuel system when fuel lines are removed. Blow dry with compressed air.

1.Disconnect ground cables from both batteries.
2.Remove air cleaner and cap intake manifold opening with intake manifold cover.
3.Disconnect accelerator cable and speed control cable, if so equipped, from injection pump.
4.Remove accelerator cable bracket from intake manifold and position out of the way with cable(s) attached.
5.Disconnect fuel line from fuel filter to injection pump and cap all fittings to prevent fuel system contamination.
6.Disconnect and cap nozzle fuel lines at nozzles.
7.Remove fuel line clamps from fuel lines to be removed.
8.Remove and cap injection pump inlet elbow.
9.Remove and cap inlet fitting adapter.

Injection Pump Cylinder Number SequenceInjection Pump Cylinder Number Sequence


10.Remove injector nozzle lines, one at a time from injection pump using fuel line nut wrench.

NOTE: Fuel lines must be removed following this sequence: 5-6-4-8-3-1-7-2. Install caps on each end of each fuel line and pump fitting as it is removed and identify each fuel line accordingly.

INSTALLATION:
1.Install fuel lines on injection pump, using fuel line nut wrench, one at a time, and tighten to 30 Nm (22 ft lb).

Fuel Line RoutingFuel Line Routing


NOTE: Fuel lines must be installed in the sequence: 2-7-1-3-8-4-6-5.

2.Clean old sealant from injection pump elbow, using clean solvent, and dry thoroughly.
3.Apply a light coating of pipe sealant with Teflon(r) on elbow threads.
4.Install elbow in injection pump adapter and tighten to 8 Nm (10 ft lb). Tighten further, if necessary, to align elbow with injection pump fuel inlet line, but do not exceed 360° of rotation or 13 Nm (10 ft lb).
5.Remove caps from fuel lines and connect to nozzles. Tighten to 30 Nm (22 ft lb) using fuel line nut wrench.
6.Uncap and connect fuel line from fuel filter to injection pump and tighten to 30 Nm (22 ft lb).
7.Install fuel line retaining clamps and tighten.
8.Install accelerator cable bracket onto intake manifold and tighten to 16-23 Nm (12-17 ft lb).
9.Connect accelerator and speed control cable, if so equipped, to injection pump throttle lever.
10.Remove intake manifold cover, and install air cleaner.
11.Connect ground cables to both batteries.

NOTE: Some abnormal drive symptoms may occur on vehicles equipped with Transmission Electronic Control Assembly (TECA) when the battery has been disconnected and reconnected. The vehicle may need to be driven 10 or more miles to relearn its adaptive strategy.

12.Run engine and check for fuel leaks.

WARNING: Keep eyes and hands away from nozzle spray. Fuel spraying from the nozzle under high pressure can penetrate the skin and cause infection. Medical attention should be provided immediately in the event of skin penetration.

13.If necessary, purge high pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until bubble-free fuel flows from connection.




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