Front Gear Train
Install a new seal ring on the front of the fuel pump assembly. Be sure the seal ring is not twisted.
Lubricate the seal ring and the mounting bore of the gear housing with clean 15W-40 engine oil.
The fuel pump driveshaft nose and drive gear shaft mating surfaces must be clean and dry prior to installation.
Wipe off the driveshaft and gear with solvent and a lintfree cloth. Do not touch the mating surfaces after wiping.
NOTE: Timing of the high-pressure pump with the crankshaft is not required.
Position the injection pump to the mounting flange on the gear housing while aligning the injection pump shaft
through the back of the injection pump gear.
After the pump is positioned flat to the mounting flange, install three pump mounting nuts (3) and hand-tighten
only.
NOTE: Do not attempt a final tightening at this time. Do not attempt to tighten (pull) the pump to gear housing
using the mounting nuts. Damage to the pump or gear housing can occur. The pump must be positioned flat to
the mounting flange before attempting to tighten the three mounting nuts.
NOTE: The engine barring tool, Part Number 3824591, can be used to prevent the crankshaft from rotating while
tightening the retaining nut.
Install the fuel pump drive gear retaining nut and lock washer.
Tighten to the initial torque value.
Torque Value: 15 Nā¢m [ 133 in-lb ]
To prevent damage or cracking of components, install and tighten in the following sequence:
Tighten the three injection pump mounting fasteners:
Torque Value: 24 Nā¢m [ 212 in-lb ]
Do a final tightening of the pump shaft nut to:
Torque Value: 105 Nā¢m [ 77 ft-lb ]
Install a new square cut o-ring onto the fuel pump drive access cover.
Install the fuel pump drive access cover with a 3/8-inch drive ratchet.
The plate is threaded into the gear cover.
Torque Value: 8 Nā¢m [ 71 in-lb ]
Rear Gear Train
Install a new seal ring on the front of the fuel pump assembly. Be sure the seal ring is not twisted.
Lubricate the seal ring and the mounting bore of the gear housing with clean 15W-40 engine oil.
NOTE: Timing of the high-pressure pump with the crankshaft is not required.
Install the fuel pump on the gear housing.
Position the injection pump to the mounting flange on the gear housing while aligning the injection pump shaft
through the back of the injection pump gear.
NOTE: The engine barring tool, Part Number 3824591, can be used to help align the gears.
After the pump is positioned flat to the mounting flange, install three pump mounting nuts (3) and hand-tighten
only.
NOTE: Do not attempt a final tightening at this time. Do not attempt to tighten (pull) the pump to gear housing
using the mounting nuts. Damage to the pump or gear housing can occur.
The pump must be positioned flat to the mounting flange before attempting to tighten the three mounting nuts.
Tighten the fuel pump mounting fasteners.
Torque Value: 24 Nā¢m [ 212 in-lb]
