GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Isuzu 🢒 2005 🢒 Isuzu MD F-Series 🢒 Engine 🢒 Engine Controls - 7.8L 🢒 Fuel Injection Pump Replacement

Removal Procedure
  1. Tilt the cab. Refer to Cab Tilting .
  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 rail pipe from the supply pump (5).

    9. Object Number: 1402407 Size: SH
  9. Remove the bracket nuts (9) and bolts (5).
  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 rail pipe 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.