Disassembly and  Assembly Section

KENR6906

i02754760

Fuel Transfer Pump - Remove

Removal Procedure

NOTICE

Care must be taken to ensure that fluids are contained

during performance of inspection, maintenance, test-

ing, adjusting and repair of the product. Be prepared to

collect the fluid with suitable containers before open-

ing any  compartment or  disassembling any  compo-

nent containing fluids.

Dispose of all fluids according to local regulations and

mandates.

NOTICE

g01380208

Keep all parts clean from contaminants.

Illustration 6

Typical example

Contaminants may cause  rapid wear and  shortened

component life.

1.  Position fuel filter base (8) onto the  mounting

bracket and install bolts (6). Tighten the bolts to a

torque of 55 N·m (41 lb ft).

1.  Turn the fuel supply to the “OFF” position.

2.  Install new O-ring seals  and new fuel filter

elements to fuel filters (9) and (10). Apply Tooling

(A) to the threads of the fuel filters. Install the fuel

filters to fuel filter base (8). Tighten the fuel filters.

2.  Place a suitable container below the fuel transfer

pump in order to catch any  fuel that might be

spilled.

Refer to Operation and Maintenance Manual,

“Fuel Filter Primary Filter - Replace” and refer to

Operation and Maintenance Manual, “Fuel Filter

Secondary Filter - Replace” for more information.

3.  Install new O-ring seals to plugs (11) and (12).

Install the plugs to fuel filters (9) and (10).

4.  Connect hose assemblies (2), (3), (4) and (5).

5.  Connect harness assembly (1) to fuel temperature

sensor (7). Slide the locking tab into the locked

position.

6.  Turn the fuel supply to the “ON” position.

7.  Remove the air from the fuel system. Refer to

Operation and Maintenance Manual, “Fuel System

- Prime”.

g01380887

Illustration 7

Typical example

3.  Disconnect hose assemblies (1) and (2) from fuel

transfer pump (4). Cap the hose assemblies.

4.  Remove bolts (3) and remove fuel transfer pump

(4).

This document has been printed from SPI². Not for Resale

KENR6906

9

Disassembly and  Assembly Section

5.  Remove the O-ring seal from fuel transfer pump

(4).

7.  Remove the air from the fuel system. Refer to

Systems Operation and Maintenance Manual,

“Fuel System - Prime”.

i02754761

Fuel Transfer Pump - Install

i02754762

Electronic Unit  Injector -

Remove

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

Removal Procedure

Table 2

Contaminants may cause  rapid wear and  shortened

component life.

Required Tools

Tool

Part Number

Part Description

Qty

1.  Ensure that the fuel transfer pump is clean and

A

27610288

Pry Bar

1

free from damage.

Start By:

a.  Remove the rocker shafts. Refer to Disassembly

and Assembly, “Rocker Shaft  and Pushrod -

Remove”.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

1.  Turn the fuel supply to the OFF position.

g01416997

Illustration 8

Typical example

2.  Lubricate a new O-ring seal with clean engine oil.

Install the O-ring seal to fuel transfer pump (4).

3.  Position fuel transfer pump (4) on pump drive (5).

g01411598

Illustration 9

Note: Ensure that the splines on the shaft of the fuel

transfer pump are correctly engaged into the pump

drive.

2.  Disconnect hoses (1) and (2) from the fuel filter

base in order to drain fuel from the cylinder head.

4.  Install bolts (3). Tighten the bolts to a torque of

55 N·m (41 lb ft).

5.  Remove the caps from the hose assemblies.

Connect hose assemblies (1)  and (2) to fuel

transfer pump (4).

6.  Turn the fuel supply to the “ON” position.

This document has been printed from SPI². Not for Resale

10

KENR6906

Disassembly and  Assembly Section

i02754763

Electronic Unit Injector - Install

Installation Procedure

Table 3

Required Tools

Tool

B

Part Number

GE50023

GE50024

GE50028

GE50046

Part Description

Tapered Brush

Qty

1

C

Small Bore Brush

Vacuum Pump

1

g01380214

Illustration 10

1

3.  Disconnect harness assembly (3) from electronic

Fluid Sampling Bottle

1

unit injector (4).

D

E

Tube

7.9 mm (0.31 inch)

OD

GE50030

1

1

4.  Remove bolt (5).

5.  Place an identification mark on electronic unit

injector (4) for  installation purposes. Each

electronic unit injector must be reinstalled in the

original location in the cylinder head.

27610296

Torque Wrench

NOTICE

Keep all parts clean from contaminants.

6.  Use Tooling (A) to pry beneath clamp (6) and free

electronic unit injector (4).

Contaminants may cause  rapid wear and  shortened

component life.

7.  Remove electronic unit injector (4) and clamp (6)

from the cylinder head.

1.  Use Tooling (B) and (C) to  clean the carbon

deposit from the inside  of the electronic unit

injector sleeve.

2.  Use Tooling (D) to remove the fuel and oil from

the cylinder. Evacuate as much fuel and  oil as

possible from the cylinder before installing the

electronic unit injector. Several evacuations may

be necessary.

g01380213

Illustration 11

8.  Remove O-ring seals (7) and (8) from electronic

unit injector (4).

g01380273

Illustration 12

3.  Ensure that seat area (X) on electronic unit injector

(4) is clean and free carbon.

This document has been printed from SPI². Not for Resale

KENR6906

11

Disassembly and  Assembly Section

4.  Install new O-ring seals (7) and (8) to electronic

unit injector (4). Lubricate the O-ring seals with

clean engine oil.

11. Remove the air from the fuel system. Refer to

Operation and Maintenance Manual, “Fuel System

- Prime”.

5.  Install a new O-ring seal (9) to  electronic unit

End By:

injector (4).

a.  Install the rocker shafts. Refer to Disassembly and

Note: O-ring seal (9) should be installed dry.

Assembly, “Rocker Shaft and Pushrod - Install”.

NOTICE

i02754765

Electronic Unit Injector Sleeve

- Remove

If a replacement electronic unit injector is installed, the

calibration code  must be programmed into  the elec-

tronic control module. Refer to Troubleshooting Guide,

“Injector Trim File” for more information.

Removal Procedure

Table 4

Required Tools

Tool

Part Number

Part Description

Qty

A

GE50021

Injector Sleeve Tool

1

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

g01380214

Illustration 13

6.  Install clamp (6) to electronic unit injector (4).

Install electronic unit injector (4) into the original

location in the cylinder head.

1.  Drain the coolant from the cooling system into

a suitable container for storage or for disposal.

Refer to Operation and Maintenance Manual,

“Cooling System Coolant - Change”.

7.  Install bolt (5). Tighten the bolt to  a torque of

55 N·m (41 lb ft).

2.  Remove the electronic unit injectors. Refer to,

Disassembly and Assembly, “Electronic  Unit

Injector - Remove”.

8.  Connect harness assembly (3) to electronic unit

injector (4). Use Tooling (E) to tighten the nuts to a

torque of 2.5 N·m (22 lb in).

g01391954

Illustration 15

g01411598

Illustration 14

3.  Install Tooling (A) into electronic unit  injector

sleeve (1).

9.  Connect hoses (1) and (2) to the fuel filter base.

10. Turn the fuel supply to the “ON” position.