Disassembly and assembly

8. Use Tooling (A) in order to plug the fuel injection
pump.
9. Remove O-ring seal (4) (not shown) and O-ring
seal (5) (not shown).
Installation Procedure
1. Ensure that all component at free from wear and
damage. If any part of the flow control valve is
worn or damaged, the flow control valve must be
replaced as an assembly.
Illustration 19 g02986577
2. Position a new O-ring seal (4) (not shown) and
new O-ring seal (5) (not shown) onto the flow
control valve assembly.
3. Check O-ring seal (4) (not shown) and O-ring seal
(5) (not shown) are correctly positioned. Ensure
that O-ring seals are not damaged.
4. Lubricate O-ring seal (4) (not shown) and O-ring
seal (5) (not shown) with clean fuel.
Note: Ensure that the O-ring seals are not damaged
or misaligned.
5. Remove Tooling (A) from the fuel injection pump.
6. Install flow control valve (3) to the fuel injection
pump.
7. Install Torx head screws (2) from the flow control
valve repair kit.
8. Tighten Torx head screws (2) equally until the flow
control valve is seated correctly onto the fuel
injection pump.
Note: Ensure that the Torx screws are tightened
equally. Failure to ensure that the Torx screws are
tightened equally will result in damage to the fuel
injection pump.
9. Tighten the Torx head screws to a torque of 9 N·m
(80 lb in).
10. Connect harness assembly (1) to flow control
valve (3).
11. Replace the filters for primary fuel system. Refer
to Operation and Maintenance Manual, “Fuel
System Primary (Water Separator) Element -
Replace” for the correct procedure.
12. Replace the filters for secondary fuel system.
Refer to Operation and Maintenance Manual,
“Fuel System Secondary Filter - Replace” for the
correct procedure.
13. Turn the fuel supply to the ON position.
14. Turn the battery disconnect switch to the ON
position.
15. Remove the air from the fuel system. Refer to
Operation and Maintenance Manual, “Fuel System
- Prime” for more information.
End By:
a. After replacement of the flow control valve, the
fuel injection pump requires a high-pressure
fuel pump calibration procedure to be
performed. Refer to Troubleshooting, “Fuel
Rail Pressure Problem” for the correct
procedure.
i05268269
Fuel Filter Base - Remove and
Install
Removal Procedure
Table 3
Required Tools
Tool Part Number
Part Description Qty
A
T412504
Capping Kit
1
UENR0624-03 13
Disassembly and Assembly Section
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