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    Remove and Install High Pressure Fuel Pump

    Uploaded by

    Wilfer Grain
    This document provides instructions for removing and installing a high pressure fuel pump on a diesel engine. It includes detailed steps and specifications for disassembling and reassembling the pump, installing it on the engine, and bleeding the fuel system.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Remove and Install High Pressure Fuel Pump

    Uploaded by

    Wilfer Grain
    136 views6 pages
    This document provides instructions for removing and installing a high pressure fuel pump on a diesel engine. It includes detailed steps and specifications for disassembling and reassembling the pump, installing it on the engine, and bleeding the fuel system.

    Original Title

    310SJ1

    Copyright

    © © All Rights Reserved

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    PDF, TXT or read online from Scribd

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    This document provides instructions for removing and installing a high pressure fuel pump on a diesel engine. It includes detailed steps and specifications for disassembling and reassembling the pump, installing it on the engine, and bleeding the fuel system.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    136 views6 pages

    Remove and Install High Pressure Fuel Pump

    Uploaded by

    Wilfer Grain
    This document provides instructions for removing and installing a high pressure fuel pump on a diesel engine. It includes detailed steps and specifications for disassembling and reassembling the pump, installing it on the engine, and bleeding the fuel system.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 6

    Page 1 of 6

    CTM502 - PowerTech™ E 4.5 and 6.8L Diesel EnginesLevel 16 Electronic


    Fuel System With Denso HPCR
    Remove and Install High Pressure Fuel Pump

    Remove and Install High Pressure Fuel Pump

    Remove High Pressure Fuel Pump

    CD30862-UN: Remove high pressure fuel pump

    CD30886-UN: Pump position sensor (high pressure pump removed)

    file:///C:/ProgramData/Service%20ADVISOR/Temp/CTM502_09001faa819a0128.html 9/23/2020
    Page 2 of 6

    CD30863-UN: Remove high pressure fuel pump

    LEGEND:

    A - Suction Control Valve


    B - Fuel Temperature Sensor
    C - Pump position sensor
    D - High pressure fuel outlet
    E - Leak-off line connection
    F - Fuel supply inlet
    G - Adapter plate nut

    1. Disconnect wiring harness from suction control valve (A), from fuel temperature sensor (B) and from pump position
    sensor (C).

    2. Remove high pressure fuel lines (D).

    3. Remove fuel leak-off line (E).

    4. Disconnect fuel supply line (F).

    5. Remove the 3 nuts (G) fixing adapter plate on engine front plate.

    6. Carefully remove high pressure pump assembly from engine.

    file:///C:/ProgramData/Service%20ADVISOR/Temp/CTM502_09001faa819a0128.html 9/23/2020
    Page 3 of 6

    CD30864-UN: High pressure fuel pump exploded view

    LEGEND:

    A - High pressure fuel pump


    B - Adapter plate
    C - Drive gear
    D - Nut
    E - O-ring
    F - Pump position sensor
    G - Fuel supply fitting
    H - Fuel leak-off fitting
    I - Cap screw (high pressure pump-to-adapter plate)

    Disassemble and Reassemble High Pressure Fuel Pump

    A) Disassembling

    1. Remove gear (C) using JDG1560 tool. Use a vise with claws to block the gear when removing gear.

    2. Remove the two cap screws (I) and separate high pressure pump (A) from adapter plate (B).

    3. Replace parts as necessary.

    B) Reassembling

    1. Install high pressure pump (A) on adapter plate (B) with a new O-ring (E). Tighten the 2 cap screws (I) to specification.

    Item Measurement Specification

    High pressure pump to adapter Torque 40 N·m (30 lb.-ft.)


    plate

    file:///C:/ProgramData/Service%20ADVISOR/Temp/CTM502_09001faa819a0128.html 9/23/2020
    Page 4 of 6

    2. Install gear (C) on pump shaft then tighten nut (D) to specification. Use a vise with claws to block the gear when
    tightening.

    Item Measurement Specification

    High pressure pump gear nut Torque 95 N·m (70 lb.-ft.)

    3. Install pump position sensor (F) onto adapter plate then tighten to specification.

    Item Measurement Specification

    Pump position sensor to adapter Torque 15 N·m (11 lb.-ft.)


    plate

    4. Install fuel supply elbow fitting (G) on high pressure pump. Orient fitting to be in line with fuel line. Tighten fitting nut to
    specification.

    Item Measurement Specification

    Fuel supply elbow fitting nut-to-high Torque 20 N·m (15 lb.-ft.)


    pressure pump

    5. Install fuel leak-off fitting (H) on high pressure pump. Orient fitting vertical pointing down. Tighten fitting nut to
    specification.

    Item Measurement Specification

    Fuel leak-off fitting nut-to-high Torque 15 N·m (11 lb.-ft.)


    pressure pump

    CD30868-UN: Install O-rings on adapter plate

    file:///C:/ProgramData/Service%20ADVISOR/Temp/CTM502_09001faa819a0128.html 9/23/2020
    Page 5 of 6

    CD30865-UN: Plug to access gear timing mark

    CD30866-UN: Gear timing mark

    CD30867-UN: Install high pressure pump

    LEGEND:

    A - Plug to access gear timing mark


    B - O-ring (adapter plate-to-front plate
    C - O-ring (camshaft sensor)
    D - High pressure pump gear timing mark
    E - High pressure fuel line
    F - Leak-off line
    G - Fuel supply line

    file:///C:/ProgramData/Service%20ADVISOR/Temp/CTM502_09001faa819a0128.html 9/23/2020
    Page 6 of 6

    H - Adapter plate nut


    I - Suction control valve
    J - Fuel temperature sensor
    K - Camshaft sensor

    Install high pressure fuel pump

    1. Rotate engine to Top Dead Center (TDC) of number 1 cylinder and install JDG1571 Timing Pin in flywheel.

    2. Remove plug (A) to access gear timing mark.

    3. Replace O-rings (B & C) on adapter plate then install high pressure pump so that timing mark (D) can be seen through
    the timing gear cover opening as shown.

    4. Install the 3 nuts (H) and tighten to specification.

    Item Measurement Specification

    Adapter plate to engine front plate Torque 40 N·m (30 lb.-ft.)

    5. Install high pressure fuel lines (E) finger tight.

    6. Initial torque. Tighten high pressure fuel line (E) to specification at both ends.

    Item Measurement Specification

    High pressure fuel line Torque 5 N·m (4 lb.-ft.)

    7. Final torque. Tighten high pressure fuel line (E) to specification at both ends.

    Item Measurement Specification

    High pressure fuel line Torque 22 N·m (16 lb.-ft.)

    Torque Turn 60 degree

    8. Install leak-off line (F) then tighten tube nuts until seated on fitting shoulder.

    9. Install fuel supply line (G) then tighten tube nut until seated on fitting shoulder.

    10. Reconnect wiring harness to suction control valve (I), to fuel temperature sensor (J) and to camshaft sensor (K).

    11. Reinstall plug (A). Tighten to specification.

    Item Measurement Specification

    Plug to access gear timing mark Torque 50 N·m (37 lb.-ft.)

    12. Bleed fuel system.

    AS58880,000115E-19-20130617

    file:///C:/ProgramData/Service%20ADVISOR/Temp/CTM502_09001faa819a0128.html 9/23/2020

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