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How to Install an Injection Pump on a 94 6 5 Turbo

General Motors manufactured an eight-cylinder 6.5-liter diesel engine from 1992 to 2000. This engine is typically turbocharged and appears in many heavy trucks from General Motors during this period. For example, A 6.5-liter turbocharged engine is an option for the 1994 Chevrolet 3/4-ton pickup truck. This engine has fuel injection and requires a pump to keep the fuel pressurized. The procedure for installing the fuel injection pump is similar for all full-size Chevrolet trucks made from 1988 to 1998.

Instructions

1

Disconnect the cable from the negative terminals of both batteries with a socket wrench. Remove the cooling fan and its shroud if necessary to access the intake manifold. Disconnect the intake manifold.

2

Detach the accelerator cable from the injection pump if applicable for your vehicle. You may also need to disconnect the retainer bracket for the air conditioning hose to gain access to the injection pump. Detach the fuel lines and electrical wiring from the injection pump. Plug the fuel lines with clean cloth.

3

Remove the vent hose assembly for the depression valve from the crankcase, including the oil filler tube. Detach the grommet from the oil filler tube. Turn the crankshaft clockwise to gain access to the bolts for the injection pump through the hole for the oil filler tube.

4

Disconnect the bolts that attach the front cover for the injection pump with a socket wrench. Remove the injection pump from the crankcase and discard its gasket.

5

Mount a new gasket to the new injection pump. Insert the pin on the hub of the injection pump into the hole on the driven gear for the injection pump. Install the injection pump and connect the front cover to the injection pump. Tighten the retaining nuts to the front cover to 30 ft. lbs. with a torque wrench.

6

Fasten the injection pump to the drive gear and tighten the bolts to 20 ft. lbs. with a torque wrench. Mount the grommet to the oil filler tube and install the vent hose assembly to the crankcase.

7

Remove the plugs from the fuel lines and attach the fuel lines to the injection pump. Tighten the bolts for the fuel lines to 20 ft. lbs. with a torque wrench. Connect the electrical wiring harness for the injection pump. Connect any additional components that you removed to access the injection pump.

8

Attach the cables to the negative battery terminals with a socket wrench. Start the engine and correct any fuel leaks.