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.

Disconnect the cables from the negative terminals of both batteries with a socket wrench. Drain the coolant from the radiator into a clean container, and store it for later use. Disconnect the shrouds from the radiator fan. Remove the radiator fan assembly with special tools T83T-6312-A and T83T-6312-B. Turn the mounting nut for the radiator fan clutch clockwise to loosen it.

Remove the electrical wiring from the alternator. Disconnect the mounting bolts for the alternator and the vacuum pump with a socket wrench. Remove the alternator and vacuum pump from the vehicle. Detach the hose for the heater from the cylinder head. Disconnect the fuel injection pump from the cover of the intake manifold with a socket wrench, and detach the intake manifold cover.

Raise the truck with a floor jack, and support it on jack stands. Remove the exhaust pipes from the exhaust manifolds. Release the clamp on the oil dipstick tube. Disconnect the mounting bolts that attach the oil dipstick tube to the cylinder head, and remove the oil dipstick tube from the vehicle. Lower the truck with the floor jack.

Disconnect the valve cover with a socket wrench. Remove the rocker arms and pushrods from the cylinder head. Record the position of each push rod and rocker arm as you remove them to ensure you install them to their original position. Remove the fuel injector nozzles and glow plugs from the engine.

Disconnect the mounting bolts for the cylinder head with a socket wrench. Attach lifting eyes to each end of the cylinder head with special tool T70P-6000. Lift the cylinder head with the lifting eyes, and remove it from the engine compartment.

Place the new cylinder head onto the engine block, while ensuring the pre-chambers dont fall into the cylinder bores. Coat the mounting bolts for the cylinder head with engine oil. Fasten the mounting bolts for the cylinder head, and tighten them in four separate passes with a socket wrench.

Coat the ends of the push rods with engine oil. Install the push rods in the positions you recorded in step four, and ensure the push rods are properly seated. Lubricate the tips of the valve stems with Lubriplate grease. Turn the crankshaft by hand to move its timing mark to the 11 oclock position. Install the rocker arms to their original, and tighten their mounting bolts to 27 foot-pounds with a torque wrench.

Replace the valve covers with a socket wrench. Install the intake manifold, and connect the fuel injection pump to the intake manifold. Attach the hose from the heater to the cylinder head. Install the alternator and vacuum pump to the engine, and connect the oil dip stick. Install the exhaust pipe to the exhaust manifolds, and attach the electrical wiring for the alternator. Connect the air cleaner to the engine.

Install the radiator clutch assembly with special tools T83T-6312A and T83T-6312B. Attach the cables to the negative battery terminals with a socket wrench. Fill the radiator with coolant, and start the engine. Check for leaks in the exhaust, coolant and fuel systems.

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.