1999 Chevy Truck K 3500 Truck 4WD V8-6.5L DSL Turbo VIN F Copyright © 2013, ALLDATA 10.

52 Page 1

Diesel MFI Pump: Service and Repair

Fuel Injection Pump
REMOVAL PROCEDURE

TOOLS REQUIRED
J 41089 Injection Pump Wrench

CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.

1. Remove the negative battery cables.

2. Remove the intake manifold.
3. Remove the injection lines.
4. Remove the fuel inlet line from the injection pump.
5. Remove all necessary harness connectors and hoses from the injection pump.
6. Remove the fuel return line at the top of the injection pump.
7. Remove the oil fill tube.
8. Remove the grommet for the oil filler tube.
9. Rotate the engine to gain access to the bolts (1) that hold the driven gear to the injection pump. Access is gained through the oil filler neck hole.
10. Remove the driven gear bolts.

IMPORTANT: Never engage the starter motor to rotate the engine when the injection pump is removed as severe engine damage will occur. With
the injection pump removed the pump driven gear could jam in the front housing by engaging the starter motor, resulting in a sheared crankshaft or
camshaft gear key and possible valve train damage. Always bar the engine over by hand to avoid internal engine damage.

11. Remove the injection pump flange nuts. Use the J 41089 injection pump wrench.
1999 Chevy Truck K 3500 Truck 4WD V8-6.5L DSL Turbo VIN F Copyright © 2013, ALLDATA 10.52 Page 2

12. Remove the injection pump.

13. Cap all open lines and nozzles.
14. Remove the flange gasket.

INSTALLATION PROCEDURE

1. Install the new flange gasket on the injection pump.

2. Adjust the locating stud (1) to the proper position to match with the slotted/elongated hole in the driven gear.

IMPORTANT: Be sure the locating stud (1) on the injection pump hub goes into the slotted/elongated hole in the driven gear.

3. Install the injection pump making sure the locating stud is positioned within the slotted/elongated hole (1) in the driven gear.

NOTE: Refer to Fastener Notice in Cautions and Notices.

1999 Chevy Truck K 3500 Truck 4WD V8-6.5L DSL Turbo VIN F Copyright © 2013, ALLDATA 10.52 Page 3

4. Install the injection pump flange nuts.

Tighten
Tighten nuts to 40 N.m (30 lb ft).

IMPORTANT: All the driven gear bolts should not be torqued until all the bolts are installed. This will allow for the proper alignment of all the bolt
holes.

5. Install the driven gear bolts (1).

Tighten
Tighten the bolts to 25 N.m (18 lb ft).

6. Install the grommet for the oil filler tube.

7. Install the oil filler tube.
8. Install the fuel feed line at the injection pump.
9. Install the fuel return line to the top of the injection pump.
10. Install all necessary harnesses and connectors.
11. Install the injection lines.
12. Install the intake manifold.
13. Install the negative battery cables.
14. Adjust the injection timing.