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For 1990-2009 cars only
Makes 🢒 Isuzu 🢒 2004 🢒 Isuzu MD F-Series 🢒 Engine 🢒 Engine Controls - 7.8L 🢒 Fuel Injection Pump Replacement

Fuel Injection Pump Replacement Without CTF

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

    2. Object Number: 814036 Size: SH
  2. Remove the oil feed pipe.

    3. Object Number: 814037 Size: SH
  3. Remove the fuel supply pump bracket from the cylinder block.
  4. Remove the fuel supply pump from the engine.

    5. Object Number: 814041 Size: SH
  5. Remove the fuel supply pump bracket under a fuel supply pump.
  6. Remove the fuel feed pipe.
  7. Remove the gear and key from the shaft in the fuel supply pump.

Installation Procedure

    Object Number: 814042 Size: SH
  1. Paint the gear surface of the punch mark.
  2. Attach the key to shaft of the fuel supply pump.

    3. Notice: Refer to Fastener Notice in the Preface section.

  3. Tighten the gear with nut and washer.

    4. Tighten
    Tighten the fuel supply pump nut to 270 N·m (199 lb ft).


    Object Number: 814037 Size: SH
  4. Install the fuel supply pump bracket to the button of fuel supply pump.
  5. Install the bracket bolt.

    6. Tighten
    Tighten the fuel supply pump bracket bolt to 56.8 N·m (41.9 lb ft).


    Object Number: 814043 Size: SH
  6. Align the fuel supply pump mark A and the gear punch mark.
  7. Number 1 cylinder should be at top dead center.

    8. Object Number: 814045 Size: SH
  8. Fit the O-ring to fuel supply pump.
  9. Install the fuel supply pump to the cylinder block.

    10. Tighten
    Tighten the fuel supply pump nut and bolt to the following torques:

    • Nut (1) to 40 N·m (30 lb ft)
    • Nut (2) to 72.5 N·m (53.5 lb ft)
    • Bolt (3) to 72.5 N·m (53.5 lb ft)

    Object Number: 814047 Size: SH
  10. Inspect the gear position from inspection hole on housing upper part.
  11. Confirm that the gear paint is verified from the inspection hole as zoom view. If not, reinstall the fuel supply pump.

    12. Object Number: 814048 Size: SH
  12. Install the fuel supply pump bracket to the cylinder block.
  13. Install the plug to the inspection hole.

    14. Important: Hand tighten the bolt first, then tighten to specified torque.

    Tighten
    Tighten the fuel supply pump bracket bolt and plug to the following torques:

    • Bolt (1) to 28.4 N·m (20.9 lb ft)
    • Bolt (2) to 56.8 N·m (41.9 lb ft)
    • Bolt (3) to 34.3 N·m (25.3 lb ft)

    Object Number: 814049 Size: SH
  14. Install the oil feed pipe.
  15. Tighten the eye bolt to the following torques:

    16. Tighten

        • Tighten the Eye bolt (1) to 7.9-12.7 N·m (5.8-9.4 lb ft).
        • Tighten the Eye bolt (2) to 27.4 N·m (20.2 lb ft).
  16. Lower the cab.

Fuel Injection Pump Replacement With CTF

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

    4. Object Number: 1401134 Size: SH
  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).
  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. Object Number: 1402407 Size: SH
  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. Object Number: 1369961 Size: SH
  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.

    2. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1369961 Size: SH
  2. If required, install the NEW O-ring (2) and the bracket (1) to the fuel supply pump (3) with 3 bolts (4).

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


    Object Number: 1401132 Size: SH
  3. Paint the gear teeth directly above the punch mark.
  4. Attach the key to the fuel supply pump shaft.

    5. Object Number: 1402407 Size: SH
  5. Install the gear (3) and nut (4).

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


    Object Number: 1369964 Size: SH
  6. Align the fuel supply pump bracket mark (1) and the gear punch mark (2).

    7. Object Number: 1402407 Size: SH
  7. Fit the gasket (6) to the fuel supply pump bracket (2).
  8. Install the fuel supply pump (1) to the cylinder block.
  9. Tighten the fuel supply pump nuts (9) and bolt (5).

    10. 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. Object Number: 1369975 Size: SH
  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. Object Number: 1401134 Size: SH
  12. Install the fuel common rail pipes (6) to the fuel supply pump (5).

    13. 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 .
  18. Bleed (prime) the fuel system and inspect for leaks. Refer to Fuel System Bleeding .
  19. Lower the cab.