1/9/2018 IsuzuTruck Electronic Service Information System

Repair Instructions
Fuel Injection Pump Replacement (With CTF)

IMPORTANT: Pressure in the fuel return line to the fuel tank(s) may cause fuel injection pump seal
damage, which may continue to damage a new fuel injection pump. If a fuel injection pump came
apart placing debris into the return line, the return line may become blocked at the narrowest
point, which generally is the fuel line restrictor on a dual fuel tank setup. If the return line is
plugged, the Actual Fuel Rail Pressure parameter on the scan tool will read noticeably higher than
the Desired Fuel Rail Pressure, especially during a cranking condition. There will be pressure in
the fuel return line as measured with a fuel gauge.

Removal Procedure
1. Tilt the cab. Refer to Cab Tilting in General Information.

2. Remove the engine control module (ECM) with bracket keeping the ECM connected. Refer to
Engine Control Module Replacement/Restore Fuel Rate Data (w/o CTF) Engine Control Module
Replacement/Restore Fuel Rate Data (w/ CTF) .

3. Turn the crankshaft to position the Number 1 cylinder at top dead center.

4. Disconnect the electrical connector at the fuel temperature sensor (3).

5. Disconnect the electrical connector at the suction control valve (7).

6. Remove the fuel suction pipe (1) from the fuel supply pump (5).

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7. Remove the fuel filter leak off pipe (2) from the supply pump (5).

8. Remove the fuel common rail pipes (6) from the supply pump (5).

9. Remove the bracket nuts (9) and bolts (5, 10).

10. Remove the fuel supply pump (1) with the bracket (2) from the engine.

11. If required, remove the gear nut (4), the gear (3) and the key from the fuel supply pump shaft.

12. If required, remove the bracket (1) and O-ring (2) from the fuel supply pump (3).

Installation Procedure
1. Ensure that cylinder Number 1 is at top dead center.

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Notice:

• Refer to Fastener Notice in Cautions and Notices.

2. If required, install the NEW O-ring (2) and the bracket (1) to the fuel supply pump (3) with 3 bolts
(4).

Tighten
Tighten the fuel supply pump bracket bolts to 19 N-m (14 lb ft).

3. Paint the gear teeth directly above the punch mark.

4. Attach the key to the fuel supply pump shaft.

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5. Install the gear (3) and nut (4).

Tighten
Tighten the gear nut to 64 N-m (47 lb ft).

6. Align the fuel supply pump bracket mark (1) and the gear punch mark (2).

7. Fit the gasket (6) to the fuel supply pump bracket (2).

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8. Install the fuel supply pump (1) to the cylinder block.

9. Tighten the fuel supply pump nuts (9) and bolt (5).

Tighten

Tighten the nuts (9) to 50 N-m (37 lb ft).

Tighten the bolt (5) to 76 N-m (56 lb ft).

10. Ensure that cylinder Number 1 is at top dead center.

11. Inspect the gear position through the inspection hole at the top of the housing. The painted
portion (1) of the gear (2) must be visible through the hole. If it is not, the pump is incorrectly
installed. Repeat the installation procedure.

12. Install the fuel common rail pipes (6) to the fuel supply pump (5).

Tighten
Tighten the fuel common rail pipe nut to 44 N-m (32 lb ft).

13. Install the fuel filter leak off pipe (2) to the fuel supply pump (5).

14. Install the fuel suction pipe (1) to the fuel supply pump (5).

15. Connect the fuel temperature sensor electrical connector (3).

16. Connect the suction control valve electrical connector (7).

17. Install the ECM with bracket. Refer to Engine Control Module Replacement/Restore Fuel Rate
Data (w/o CTF) Engine Control Module Replacement/Restore Fuel Rate Data (w/ CTF) .

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18. Bleed (prime) the fuel system and inspect for leaks. Refer to Fuel System Bleeding (Without
CTF) Fuel System Bleeding (With CTF) .

19. Lower the cab.

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