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Home >> GMC >> 2002 >> C3500 HD 6.5 F, Standard >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - 6.5L >> Repair Instructions >> Fuel Injection Pump Replacement >> Removal Procedure
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Removal Procedure

CAUTION: Refer to BATTERY DISCONNECT CAUTION .
  1. Remove the negative battery cables.
  2. Remove the intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT - UPPER and INTAKE MANIFOLD REPLACEMENT - LOWER .
  3. Remove the injection lines. Refer to Fuel Injection Line(s) Replacement .
  4. Remove the fuel inlet line from the injection pump.
  5. Remove all necessary harness connectors and hoses from the injection pump.
  6. Remove the fuel return line at the top of the injection pump.
  7. Remove the oil fill tube.
  8. Remove the grommet for the oil filler tube.
  9. Rotate the engine to gain access to the bolts (1) that hold the driven gear to the injection pump. Access is gained through the oil filler neck hole.
  10. Remove the driven gear bolts.
    Fig 1: Driven Gear Bolts
    G01599586Courtesy of GENERAL MOTORS CORP.

    Important:  Never engage the starter motor to rotate the engine when the injection pump is removed as severe engine damage will occur. With the injection pump removed the pump driven gear could jam in the front housing by engaging the starter motor, resulting in a sheared crankshaft or camshaft gear key and possible valve train damage. Always bar the engine over by hand to avoid internal engine damage.

  11. Remove the injection pump flange nuts. Use the J 41089  injection pump wrench.
    Fig 2: Injection Pump Flange Nuts
    G01599587Courtesy of GENERAL MOTORS CORP.
  12. Remove the injection pump.
  13. Cap all open lines and nozzles.
  14. Remove the flange gasket.
    Fig 3: Fuel Injection Pump
    G01599588Courtesy of GENERAL MOTORS CORP.
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