Orlando

Fuel Injection Pump Replacement

Special Tools

For equivalent regional tools, refer to Special Tools .

1. Remove the engine sight shield. Refer to Engine Sight Shield Replacement .
2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .
3. Remove the engine control module. Refer to Engine Control Module Replacement .



4. Remove the charge air cooler outlet front hose bracket bolt (2).
5. Loosen the charge air cooler outlet front hose to rear hose clip (4).
6. Detach the charge air cooler outlet front hose (1) along with the clamp (4) from the charge air cooler outlet rear hose (3). Hang the charge air cooler outlet front hose aside (1).



7. Unclip the 4 engine wiring harness retaining clips from the engine wiring harness bracket.
8. Remove the 2 engine wiring harness bracket and engine water outlet adaptor bolts (2) from the engine water outlet adaptor.
9. Remove the engine wiring harness bracket (1) from the engine water outlet adaptor.



10. Disconnect the fuel injection pump wiring harness plug (4).
11. Remove the fuel injection fuel return hose (3).
12. Disconnect the fuel feed front pipe (5) and unclip from the fuel return front pipe clip. Refer to Plastic Collar Quick Connect Fitting Service .
13. Close the fuel return front pipe with the EN-6015 closure plugs .
14. Disconnect the fuel return front pipe (2), using the EN-796 remover . Refer to Plastic Collar Quick Connect Fitting Service .
15. Remove the fuel injection fuel feed pipe (1). Refer to Fuel Injection Fuel Feed Pipe Replacement - Fuel Injection Pump to Fuel Rail .
16. Close the fuel injection fuel feed pipe with the EN-807 closure plugs .



17. Remove the 3 injection pump bolts (3).
18. Remove the injection pump (2) and the gasket (1).

1. Install the injection pump (2) and a NEW gasket (1).

Caution: Refer to Fastener Caution in the Preface section.

2. Install the 3 injection pump bolts (3) and tighten to 25 N·m (18 lb ft).



3. Remove the EN-807 closure plugs from the fuel injection fuel feed pipe (1).
4. Install the fuel injection fuel feed pipe (1). Refer to Fuel Injection Fuel Feed Pipe Replacement - Fuel Injection Pump to Fuel Rail .
5. Remove the EN-6015 closure plugs from the fuel return front pipe (2).
6. Connect the fuel return front pipe (2). Refer to Plastic Collar Quick Connect Fitting Service .
7. Connect the fuel feed front pipe (5) and clip to the fuel return front pipe clip. Refer to Plastic Collar Quick Connect Fitting Service .
8. Install the fuel injection fuel return hose (3).
9. Connect the fuel injection pump wiring harness plug (4).



10. Install the engine wiring harness bracket (1) to the engine water outlet adaptor.
11. Install the 2 engine wiring harness bracket and engine water outlet adaptor bolts (2) to the engine water outlet adaptor and tighten to 10 N·m (89 lb in).
12. Clip the 4 engine wiring harness retaining clips into the engine wiring harness bracket.



13. Install the charge air cooler outlet front hose (1) along with the clamp (4) to the charge air cooler outlet rear hose (3).
14. Install the charge air cooler outlet front hose bracket bolt (2) and tighten to 9 N·m (80 lb in).
15. Tighten the charge air cooler outlet front hose to the rear hose clip (4) to 4 N·m (35 lb in).
16. Install the engine control module. Refer to Engine Control Module Replacement .
17. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .
18. Install the engine sight shield. Refer to Engine Sight Shield Replacement .