Fix It

Detach the cables from the negative battery terminals with a socket wrench. Disconnect the bracket for the throttle linkage and remove the throttle linkage. Remove the fuel drain manifold and detach the fuel lines from the injection pump. Disconnect the fuel air control tube and electrical connector for the fuel shutoff valve. Remove the bracket and the oil fill tube from the injection pump.

Cover the opening in the injection gear cover with a shop towel to keep parts out of the gear housing. Disconnect the retaining nut and washer for the injection gear with a socket wrench.

Turn the crankshaft clockwise by hand until the key way on the shaft of the fuel pump points straight down. Push the top dead center pin on the crankshaft as you turn the crankshaft clockwise. Stop turning the crankshaft when the pin drops into the timing hole on the crankshaft gear.

Loosen the lock screw on the injection pump with a socket wrench, and remove its washer. Tighten the locks screw to 22 foot-pounds with a torque wrench to lock the drive shaft in place.

Remove the drive gear for the injection pump from the crankshaft and unfasten the mounting nuts for the injection pump. Remove the injection pump and its gasket from the engine. Clean the mounting surfaces for the gasket with a shop towel.

Install the new injection pump and its gasket to the engine. Tighten its mounting nuts by hand, so that the pump can still move freely within its slots. Connect the drive gear for the injection pump to the crankshaft. Tightened the retaining nut for the drive gear to between 11 and 15 foot-pounds with a torque wrench.

Turn the injection pump counterclockwise to seat the drive gear for the injection pump. Tighten the mounting nuts for the injection pump to 18 foot-pounds with a torque wrench. Loosen the lock screw for the injection pump with a socket wrench, so you can install the washer. Tighten the lock screw to 13 foot-pounds and remove the top dead center pin from the timing hole.

Install the bracket for the injection pump and tighten the retaining bolt for the injector gear to 48 foot-pounds with a torque wrench. Replace the oil filler tube and the electrical connector for the fuel shutoff valve. Install the fuel air control tube with a socket wrench and attach the fuel lines to the injection pump. Connect the fuel drain manifold and throttle linkage. Attach the cable for the negative battery terminal.

Turn the bleed bolt on the fuel pipe counterclockwise with a socket wrench. Push the button on the fuel transfer pump to bleed the air from the fuel system. Tighten the bleed bolt to 72 inch-pounds with a torque wrench.

Relieve the pressure in the fuel system as follows: Remove the fuel filler cap; Disconnect the fuel pump relay; Run the engine until it stops. Be sure to reinstall the relay when you have completed the repairs. Disconnect the negative cable from the battery. Be sure to disengage the security system before disconnecting the battery.

Drain the engine coolant into a container and save it for re-use or recycling. Remove the spark plugs, timing belt covers, the timing belt, camshaft sprockets and camshafts. Follow the procedures to mark the components in order to re-install the camshafts properly.

Remove the intake and exhaust manifolds (use the penetrating oil to loosen the bolts if necessary) and any other brackets, hoses or components blocking access to the heads.

Loosen the head bolts in the reverse order they are installed: Start with the outside bolts in an "X" pattern and loosen the center bolts last. The erence below will indicate the exact sequence. Remove the heads and place a clean towel in each cylinder to prevent contamination.

Clean the gasket mating surfaces caully and thoroughly. Install the new gaskets on the head locating lugs and install the heads with the bolts finger tight. Use the torque wrench and angle indicators in the tightening sequence and procedures to complete the installation process. Assemble the other parts in reverse of the order they were removed.

Disconnect the negative battery cable with a socket wrench to prevent sparking. Open the filler cap for the fuel tank to relieve the pressure in the fuel tank.

Wrap a shop towel around the banjo bolt on top of the fuel filter. Hold the fuel filter with an open-end wrench. Loosen the banjo bolt slowly by one complete turn with a box-end wrench to relieve the pressure in the fuel system. Tighten the banjo bolt to its original position with the box-end wrench.

Remove the rear seat cushion and open the access panel on the floor of the passenger compartment. Disconnect the electrical connector from the fuel pump.

Remove the mounting nuts for the fuel pump with a socket wrench. Lift the fuel pump from the fuel tank.

Place the new fuel pump into the fuel tank and fasten the mounting bolts with a socket wrench. Attach the electrical connector for the fuel pump. Close the access panel and replace the rear seat cushion. Reconnect the negative battery cable.

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.

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.

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.

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.

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.

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.

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.

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

Remove the negative battery cable with a socket wrench, so that you do not inadvertently start the engine. Disconnect the air cleaner assembly from the valve covers, including the air filter. Detach the air crossover, and cover the intake manifold with screen cover No. J-26996-1.

Disconnect the return spring for the throttle rod, and detach the throttle rod from the intake manifold with a socket wrench. Remove the bell crank from the intake manifold. Detach the transmission and throttle cables from the brackets of the intake manifold.

Remove the fuel lines from the fuel filter, and disconnect the fuel filter with a socket wrench. Detach the fuel send line from the fuel injection pump. Disconnect the rear brace for the air compressor.

Detach the fuel return line from the fuel injection pump. Release the clamps from the fuel return line, and disconnect the fuel return lines from the fuel injector nozzles with a pair of box-end wrenches.

Disconnect the three retaining nuts for the fuel injection pump with injector pump wrench No. J-26987, and remove the fuel injection pump from the vehicle. Plug the fuel lines and nozzles with clean cloth to keep debris out of them.

Remove the cable from the negative battery terminal with a socket wrench. This prevents the engine from starting during the fuel injector removal.

Disconnect the throttle linkage and its bracket with a socket wrench, if necessary, to access the fuel injectors. The fuel injectors for the 5.9-liter engine are on the left side of the cylinder head.

Detach the fuel lines from the fuel injectors. Each of the six fuel injectors has its own high-pressure fuel line. Disconnect the mounting bolts for the fuel drain manifold with a socket wrench and remove the manifold from the engine.

Unscrew the fuel injectors with a deep well socket and remove them from the injector bores. Discard the copper washer from the diesel injector and use a new washer when you install the fuel injector.

Clean the injector bore and surrounding area with a wire brush to remove any combustion deposits.