This task covers:
General mechanic's tool kit:
Fuel injection pump boot removed
General Safety Instructions
Do not perform this procedure near fire, flames,
Diesel fuel is highly flammable. Do not perform this procedure
near fire, flames, or sparks. Severe injury or death will result.
Cover or plug all hoses, connections, and openings immediately
after disconnection or component removal to prevent
The fuel injection pump replacement procedures for pre-1990,
1990 and above 6.2 L and 6.5 L engines, are basically the same.
Refer to engine decal model number on left rocker arm cover
before ordering replacement parts, since replacement parts are not
Have drainage container available to catch fuel.
Loosen two fuel injection line nuts (2) and disconnect fuel injection lines (3) from fuel injection
Remove screw-assembled washer (4) and clamp (5) from support bracket (8).
Tag fuel injection lines by cylinder number for assembly.
Loosen two fuel injection line nuts (2) and remove fuel injection lines (3) from fuel injection pump (1).
Remove clamp (5) and two grommets (6) from fuel injection lines (3).
Inspect fuel injection lines (3) for cracks, bends, or damage. Replace if cracked, bent, or damaged.
Inspect grommets (6) for damage. Replace if damaged.