C 3500 Truck 2WD V8-6.6L DSL Turbo VIN 1 (2002)
Diesel MFI Pump: Service and Repair
Fuel Injection Pump
REMOVAL PROCEDURE
CAUTION: Refer to Battery Disconnect Caution in Service Precautions.
1. Disconnect negative battery cables from both batteries.
2. Remove the air intake duct between the air cleaner and the turbocharger inlet housing.
IMPORTANT: Cover the air intake pipe end with duct tape to prevent the infiltration of dirt.
3. Drain the coolant. Refer to Draining and Filling Cooling System in Cooling System.
4. Remove the upper fan shroud.
5. Remove the fan blade assembly.
6. Remove the serpentine belt.
7. Remove the bolt holding the positive battery cable junction box and bracket and move out of the way.
IMPORTANT: Remove only the air conditioning/power steering bracket. Do not discharge the A/C or remove the A/C and power steering lines.
8. Remove the A/C compressor.
9. Remove the power steering pump.
10. Position the A/C compressor and power steering pump aside.
11. Remove the oil filler tube.
12. Remove the air conditioning/power steering bracket.
13. Remove the alternator.
14. Remove the thermostat housing bracket, wiring and fuel test port, and two nuts.
15. Remove the positive crankcase ventilation (PCV) catch tank from the PCV bracket and bolt below holding lower line, and reposition.
16. Remove the alternator bracket.
17. Remove the turbo cooling hose return line clamp and hose.
18. Remove the upper radiator hose at the outlet pipe. Remove the bracket and support the bracket at the valve cover, and swing out of the way.
19. Remove bolt holding wiring support bracket at thermostat housing.
20. Move the main wiring harness by disconnecting the following:
^
The fuel pressure regulator connector on the fuel injection pump
^
The fuel injection control module connectors
21. Flip the wire harness and harness tray towards the back and set aside.
22. Disconnect the heater pipe bolt and temperature sensor wire from the thermostat housing.
23. Remove the air intake pipe.
24. Remove the water crossover assembly.
25. Remove the hose to the turbo water feed line.
IMPORTANT: Cap all of the open fuel connections with suitable plastic plugs in order to prevent infiltration of dirt.
26. Disconnect all high pressure fuel lines and remove supply pipe and hose at the fuel injection pump and function block.
27. Remove the return fuel hose from fuel injection pump.
28. Disconnect the y-junction banjo fitting at the junction block.
29. Remove the bolts holding the fuel injection pump, two bolts in front cover and two bolts in the block.
