Remove and discard the two O-rings on the unit pump shaft.
Repairing the Unit Pump Solenoid
A Unit Pump Solenoid repair kit (P/N: 0120740001) is now available for repair of the unit pump. This service kit is used to repair fuel leakage at the solenoid. For this type of complaint, total replacement of the unit pump is no longer necessary. Perform the following steps to install the unit pump repair kit.
To avoid injury from penetrating fluids, do not put your hands in front of fluid under pressure. Fluids under pressure can penetrate skin and clothing.
To avoid injury from fire, keep all potential ignition sources away from diesel fuel, including open flames, sparks, and electrical resistance heating elements. Do not smoke when refueling.
Identify the failed unit pump and failure mode (fuel leak at the solenoid). Remove the failed unit pump.Refer to section for unit pump removal procedure. See Figure
1. Stop Plate
2. Unit Pump
8. Model Plate
3. Anchor Plate
9. Cross Piece
5. Intermediate Plate
Unit Pump Components
Wipe the pump clean, removing excess fuel.
Remove the O-rintgs from the unit pump. Push the uni tpump )-ring installer (J-45373) onto the unit pump. This will prevent dirt from entering the unit pump holes.
Mark the position of the intermediate plate in relation to the unit pump body (See arrow A of see Figure
45306) and rest the unit pump on the stop plate. Use a pencil or scriber for marking. Do not use any stamping tools.
1. Intermediate Plate
3. Torx Bit
Removing the Magnet and Intermediate Plate
Remove all traces of paint from screw heads. Remove screws using the torx bit (P/N: 9045890210/00) and lift off the magnet together with the intermediate plate and model plate. (See arrow B of see Figure
The torx bit (P/N: 9045890210/00) can be ordered through DDC and FLCParts Distribution Centers.
Remove the intermediated plate and the model plate from the magnet. Wipe clean the sealing surface on the magnet, removing any excess fuel. Clean the model plate and remove paint from the screw heads contact area.
Remove the two spacer seals and clean the intermediate plate. Do not damage sealing surfaces.
Mark the cross piece and anchor plate in relation to the unit pump. (See arrow C of see Figure
45307). Use a marker; do not use a scriber or stamping tool. The cross piece should not be moved or twisted.
1. Unit Pump
3. Cross Piece
2. Anchor Plate
Marking the Cross Piece and Anchor Plate
Wipe clean the sealing surfaces on the unit pump, cross piece, and anchor plate, removing any excess fuel. Clean the parts thoroughly. Do not remove the paint on the unip pump; it is used as a referenece point for the intermediate plate assembly.
Remove the stop plate.
Place a new stop plate under the unit pump body.
Install the new seals in the intermediate plate. Protect the seals with a thin layer of high-temperature grease.
Place the intermediate plate on the unit pump body. Observe the identification mark on the cross piece and anchor plate for the unit pump body. The cutouts (see arrows D of see Figure
45308) at the opening in the intermediate plate must face towards the cross piece. The painted surface is a reference mark to intermediate plate assembly on the unit pump.
1. Anchor Plate
3. Intermediate Plate
2. Cross Piece
Installing the Intermediate Plate
Place the magnet on the intermediate plate and place the model plate on the magnet.
Secure the model plate, magnet, intermediate plate, unit pump and stop plate together using new screws. Hand tighten.
Tighten the screws in a crosswise pattern to 5 Nm (4 lbft), using torx bit (P/N: 9045890210/00).
Push the unit pump O-ring installer (J-45373) onto the unit pump.
Install new O-rings on the unit pump and install the unit pump in the engine.Refer to section for installation procedures.
Injector Unit Pump Installation
Install the injector unit pump as follows:
Lubricate two new O-rings with a light coating of engine oil.