REMOVAL & INSTALLATION
The fuel transfer pump is located on the left side of the engine and above the starter motor.
- Disconnect both negative battery cables.
- Thoroughly clean the area around the pump to prevent fuel contamination.
- Remove the starter motor.
- Place a drain pan beneath the pump.
- Remove the fuel line fittings.
- Disconnect the fuel line banjos, or clamps and hose, as fitted.
- Disconnect the electrical connector.
- Unfasten the mounting bolts or nuts, then remove the fuel pump (and fuel heater assembly, as fitted) from the engine.
- Clean the mating surfaces of the fuel heater mounting bracket, the fuel pump and the engine block of any gasket material.
- Position the new gaskets, the fuel heater housing mounting bracket and the fuel pump to the engine.
- Assemble, but do NOT tighten banjos, yet.
- Install mounting nuts, if fitted, but do NOT tighten yet.
- Install bracket, if fitted.
- Install the bolts if fitted, tightening them ALTERNATELY to 18 ft. lbs. (24 Nm). If mounting nuts are used, tighten to 9 ft. lbs. (12 Nm). Bracket torque is the same.
- Install the fuel line fittings to the pump and fuel heater, tightening them to 18 ft. lbs. (24 Nm).
- Install the starter motor.
- Connect the negative battery cables.
- Bleed the fuel system of air.
LOW PRESSURE BLEEDING
A certain amount of air becomes trapped in the fuel system when components on the supply and/or high pressure side are serviced or replaced.
- Loosen the low-pressure bleed bolt.
- Operate the rubber push-button primer on the fuel transfer pump. Do this until the fuel exiting the bleed screw is free of air. If the primer button feels as if it is not pumping, rotate (crank) the engine approximately 90º, then continue pumping as described.
- Tighten the low pressure bleed screw to 6 ft. lbs. (8 Nm).
Primary air bleeding is accomplished using the electric fuel transfer (lift) pump. If the vehicle has been allowed to run completely out of fuel, the fuel injectors must also be bled as the pump is not self-bleeding.
- Loosen, but do NOT remove, the banjo bolt holding the low pressure fuel supply line to the side of the fuel injection pump. Place a rag around the banjo fitting to catch excess fuel.
- Turn the key to the CRANK position and quickly release it to the ON position before the engine starts. This will operate the fuel transfer pump for about 25 seconds.
- Repeat the procedure, if needed, until fuel appears at the supply line.
- Tighten the banjo bolt to 18 ft. lbs. (24 Nm).
- If the engine will not start, crank it for 30 seconds at a time until it starts.
- If necessary, loosen the high-pressure fuel line fittings at the three rear-most cylinders. Continue until engine runs smoothly. Tighten fittings to 28 ft. lbs. (38 Nm).