eseries van 2006-2007

Injection Pump


Removal & Installation

7.3L Engines
from late 1998

Click image to see an enlarged view

Fig. Injection pump assembly components-19981/2-03 7.3L diesel engines

The fuel system remains under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Before servicing the vehicle, refer to the Precautions Section.
  3. Remove or disconnect the following:

    Negative battery cable
    Turbocharger assembly
    Fuel system pressure
    Fuel line banjo bolt at the pump
    Fuel line fittings at the rear of the cylinder heads
    Fuel lines
    The 3 hose clamps at the injection pump fittings
    Water drain hose at the fuel filter
    Filter and position it forward
    Injection pump retaining bolts, then lift the pump out of the crankcase bore
    Injection pump tappet from the crankcase bore


To install:

  1. Rotate the engine so the injection pump eccentric is on the base circle.
  3. Install or connect the following:

    Injection pump tappet in the base of the injection pump
    O-ring on the injection pump base
    Injection pump and tighten the bolts to 19-27 ft. lbs. (26-37 Nm)
    Fuel filter and connect the water drain hose
    The 3 fuel hoses at the front of the injection pump
    The fuel line clamps
    Fuel filter retaining bolts
    Fuel line assembly and new seal rings at the rear of the pump
    Fuel line fittings at the rear of the cylinder heads
    Fuel line banjo fitting at the pump. Tighten the bolt to 18 ft. lbs. (24 Nm).
    Turbocharger assembly
    Negative battery cable