MBE 4000 – Section 2.12 Fuel Pump

Section 2.12
Fuel Pump

Perform the following procedures for removal and installation of the fuel pump.‪

Section 2.12.1
Fuel Pump Removal

Remove the fuel pump as follows:‪

FIRE ‪
To avoid injury from fire, keep all potential ignition sources away from diesel fuel, including open flames, sparks, and electrical resistance heating elements. Do not smoke when refueling.‪

1. Disconnect the batteries.
2. Open the fuel tank fill cap to release the pressure in the fuel system. Replace and tighten the cap.

   PERSONAL INJURY ‪
   To avoid injury from the sudden release of a high-pressure hose connection, wear a face shield or goggles.‪

3. Remove the fuel lines from the fuel pump. Discard the seal rings on the banjo fitting. See Figure "Fuel Lines at the Fuel Pump" .
   

   1. Fuel Pump‪	3. Banjo (Hollow-Core) Bolt‪
   2. Banjo Fittings‪

   Figure 1. Fuel Lines at the Fuel Pump

   Note: Catch any fuel that runs out of the fuel pump or the fuel lines.

4. Remove the socket-head bolts attaching the fuel pump to the cylinder block. Discard the gasket.
5. Slowly remove the fuel pump from the engine, taking care not to damage the spline shaft on the fuel pump.
6. Discharge the fuel pump gasket.

Section 2.12.2
Fuel Pump Installation

Install the fuel pump as follows:‪

1. Install the fuel pump on the cylinder block. See Figure "Fuel Pump Shaft" .
   

   1. Spline Shaft‪

   2. Fuel Pump‪

   Figure 2. Fuel Pump Shaft

   1. Install a new gasket on the connection to the cylinder block.
   2. Work the spline shaft slowly and carefully into the opening in the cylinder block until it meshes with the camshaft drive gear.
   3. Install and tighten the three socket-head bolts that attach the fuel pump to the cylinder block. Tighten the socket-head bolts to 25 N·m (18 lb·ft).

   PERSONAL INJURY ‪
   To avoid injury from the sudden release of a high-pressure hose connection, wear a face shield or goggles.‪

2. Install the fuel lines, as removed. Install new seal rings on the banjo fittings. Tighten the banjo bolts to 40-50 N·m (30-37 lb·ft).
3. Connect the batteries.

   PERSONAL INJURY ‪
   Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.‪ Always start and operate an engine in a well ventilated area. If operating an engine in an enclosed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system or emission control system.

4. Prime the fuel system.
5. With the engine running, check the fuel pump and the rest of the fuel system for leaks. Shut down the engine.