MBE 900 – Section 2.15 Fuel Pump

Section 2.15
Fuel Pump

The gear-type fuel pump is bolted to the front of the cylinder block. The pump is driven from the forward end of the camshaft.‪

Section 2.15.1
Fuel Pump Removal

Remove the fuel pump as follows:‪

1. Release the tension on the serpentine belt. Remove the belt from the idler pulley.
2. Remove the crossover (cold air intake) hose that leads from the charge air cooler to the charge air inlet.
3. Remove the fan from the fan clutch and set it aside within the fan shroud.
4. On vehicles with air conditioning only, remove the idler pulley from the fuel pump.

   FIRE ‪

   To avoid injury from fire caused by heated diesel-fuel vapors:‪ Keep those people who are not directly involved in servicing away from the engine. Stop the engine immediately if a fuel leak is detected. Do not smoke or allow open flames when working on an operating engine. Wear adequate protective clothing (face shield, insulated gloves and apron, etc.). To prevent a buildup of potentially volatile vapors, keep the engine area well ventilated during operation.

5. Using a 36-mm socket wrench insert, unscrew the cap on the main fuel filter. See Figure "Fuel Pump Removal" .
   

   1. Mounting Bolts (3 qty.)‪	5. O-ring‪
   2. Fuel Pump‪	6. Banjo Bolt‪
   3. Gasket‪	7. Seal Ring‪
   4. Cap (fuel filter)‪	8. Banjo Fitting‪

   Figure 1. Fuel Pump Removal

6. Remove the fuel line from the fuel pump. Discard the seal rings on the banjo fitting.

   Note: Collect any fuel that runs out of the fuel pump or the fuel line.

7. Remove the fuel pump from the crankcase. Discard the gasket.

   Note: Collect any fuel that runs out of the fuel pump or the fuel line.

Section 2.15.2
Fuel Pump Installation

Install the fuel pump as follows:‪

1. Install the fuel pump. Install a new gasket on the connection to the crankcase. Tighten the three mounting bolts 25 N·m (18 lb·ft).
2. Install the fuel line, as removed. Install new seal rings on the banjo fittings. Tighten the banjo bolts 40 N·m (30 lb·ft).
3. Check the O-ring on the main filter cap and replace it if necessary. Screw the cap onto the filter housing. Tighten the cap 25 N·m (18 lb·ft).
4. Install the idler pulley guide on the fuel pump.
5. Install the fan on the fan clutch, as removed.
6. Install the crossover (cold air intake) hose between the charge air cooler and the charge air inlet, as removed.
7. With the belt tension released, install the serpentine belt on the idler pulley. Restore the belt tension.
8. Bleed the fuel system.
   1. Make sure that all high-pressure lines have been tightened to 25 N·m (18 lb·ft) and all banjo bolts to 40 N·m (30 lb·ft).
   2. Correct torque on the high-pressure lines is critical. Incorrect torques could result in leaks or lack of power due to restricted fuel flow.
   3. If equipped with a hand pump on the fuel/water separator, work the hand pump 50 times.

   PERSONAL INJURY ‪
   To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked.‪

   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.

9. Crank the engine for 30 seconds at a time, but no longer . Before cranking the engine again, wait at least two minutes. The engine should start within four 30-second attempts.