Mechanics

GMC OTHER FUEL INJECTION PROBLEM

2005 GMC Other

Question is for 2005 GMC C5500 Disel.
How to install the fuel injection pump?
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Ruth2013
January 3, 2013.




FUEL INJECTION PUMP REPLACEMENT

REMOVAL PROCEDURE

Remove the intake manifold cover.
Disconnect negative battery cable.
Remove the air cleaner outlet duct.
Remove the fuel injection control module.
Drain the cooling system. Refer to Draining and Filling Cooling System (w/RPO HP2) Draining and Filling Cooling System (w/o RPO HP2).
Remove the fan.
Remove the battery cable junction block bolt (1) from the power steering pump bracket.
Reposition the battery cables out of the way.

Disconnect the air conditioning (A/C) compressor clutch electrical connector.
Disconnect the A/C cut out switch electrical connector.
Remove the A/C compressor bolts.
Reposition the A/C compressor, with the hoses attached, to the right side of the engine compartment.

Remove the power steering pump bracket rear bolts (1).
Reposition the power steering pump, with the hoses attached, to the right side of the engine compartment.

Remove the A/C compressor/power steering pump bracket bolts and bracket.
Remove the oil fill tube.

Remove the oil level indicator tube bracket bolt.
Remove the heater outlet hose bolt from the generator bracket.

Remove the drive belt tensioner bolt and tensioner.

Remove the generator.
Remove the generator bracket bolts and bracket.
Remove the thermostat housing crossover.
Remove the air intake pipe.

Disconnect the fuel balance pipe fitting from the right fuel rail.
Remove the fuel balance pipe retainer bolts.

Disconnect the fuel rail inlet pipe from the injection pump and rail.
Remove the inlet pipe.

Reposition the injection pump hose clamps at the fuel line.
Remove the hoses from fuel lines.

Remove the fuel injection pump bolts.

IMPORTANT: Be careful not to damage any mating surfaces.

Remove the fuel injection pump from the block. Use 2 screwdrivers to work the pump from the block towards the rear of engine keeping the pump straight.
The fuel injection pump may need to be rotated in order to remove it from the vehicle.

PREPARING THE FUEL INJECTION PUMP

Hold the fuel pump by the drive gear in a vice with copper jaw liners.
Loosen the gear nut until the nut is even with the end of the gear shaft.
Remove the gear from the tapered shaft of the injection pump.
Separate the injection pump and adapter by removing the 3 bolts and spacers.
Inspect the O-ring for damage on the pump adapter and replace, if necessary. Lubricate the O-ring with clean engine oil.
Clean all mating surfaces.
Install the adapter on the pump.

NOTE: Refer to Fastener Notice in Service Precautions.

Install the 3 bolts and spacers.

Tighten the bolts to 20 N.M (15 lb ft).

Install the gear and nut.

Tighten nut to 70 N.M (52 lb ft).

INSTALLATION PROCEDURE

Install the fuel injection pump to the block.
Install the fuel injection pump bolts.

Tighten the bolts to 21 N.M (15 lb ft).

Install the hoses to fuel lines.
Position the injection pump hose clamps at the fuel line.

Install the inlet pipe.
Connect the fuel rail inlet pipe to the injection pump and rail.

Tighten the fittings to 41 N.M (30 lb ft).

Connect the fuel balance pipe fitting to the right fuel rail.

Tighten the fitting to 41 N.M (30 lb ft).

Install the fuel balance pipe retainer bolts.

Tighten the bolts to 10 N.M (89 lb in).

Install the air intake pipe.
Install the thermostat housing crossover.
Install the generator bracket and bolts.

Tighten the bolts to 46 N.M (34 lb ft).

Install the generator.

Install the drive belt tensioner and bolt.

Tighten the bolt to 50 N.M (37 lb ft).

Install the heater outlet hose bolt to the generator bracket.

Tighten the bolt to 21 N.M (15 lb ft).

Install the oil level indicator tube bracket bolt.

Tighten the bolt to 21 N.M (15 lb ft).

Install the oil fill tube.
Install the A/C compressor/power steering pump bracket and bolts.

Tighten the bolt to 46 N.M (34 lb ft).

Position the power steering pump, with the hoses attached, to the bracket.
Install the power steering pump bracket rear bolts (1).

Tighten the bolts to 50 N.M (37 lb ft).

Position the A/C compressor, with the hoses attached, to the bracket.
Install the A/C compressor bolts.

Tighten the bolts to 50 N.M (37 lb ft).

Connect the A/C cut out switch electrical connector.
Connect the A/C compressor clutch electrical connector.

Position the battery cables to the bracket.
Install the battery cable junction block bolt to the power steering pump bracket.

Tighten the bolts to 9 N.M (80 lb in).

Install the fan.
Install the fuel injection control module.
Fill the cooling system. Refer to Draining and Filling Cooling System (w/RPO HP2) Draining and Filling Cooling System (w/o RPO HP2) in Cooling System.
Install the air cleaner outlet duct.
Connect negative battery cable.
Install the intake manifold cover.
Prime the fuel system. Refer to Fuel System Priming.
Start the engine. If the engine stalls, repeat the above step.
Once the engine starts, inspect for fuel leaks.

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pump is about 900

14 hours in labor for a shop. Very tough job at home

Roy



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