My truck is leaking diesel from around the fittings coming out of my injector pump. I am going to have to remove some of the fittings in order to reach the fittings closest to the engine block. Am I doing this the hard way? What problems (If any) am I going to encounter while doing this? Am I going to have to bleed the fuel system afterwards?

Any suggestions would sure be appreciated.

Thanks.

 

I do not see which year you have, that makes a significant difference on the procedure.

 

2002 automatic

 

Ok, that is pretty straight forward. The biggest hurdle is getting the electrical components disconnected and various parts out of the way, but first disconnect your negative battery cables - this is critical to avoid nuking your pump by accident.

It takes two small screwdrivers to pry the front wiring harness clip out of the cable bracket, then lay the entire wiring harness toward the front of the engine and out of the way.

Remove the wiring harness clip from the APPS, and unplug the connector to the APPS.

It is easiest to remove the oil dip stick tube and the air horn. Watch the ground cable and make sure you move it forward out of the way. Pull the grid heaters and then plug the hole in the intake with a large rag to keep junk from dropping in.

Remove the three cable bracket mounting bolts, and set the bracket with the cables still connected to the side out of the way.

Remove the rear engine lifting bracket.

Remove all brackets from the high pressure lines, this is necessary to remove any tension or strain on those lines.

Remove the high pressure fittings for 1, 2 and 4 from the pump, and at the other end of each of those lines. Those lines are then lifted out of the way as a complete group.

Now you are ready to tighten the fittings on 3, 5 and 6.

Tighten them with fitting wrenches, not regular open end wrenches. They should be set to 28 foot pounds on both ends. No more, and no less. Get them too tight and they will deform and you are hosed!

Then reinstall the lines you removed to gain access to the loose lines, and tighten them the same.

Once done with the lines, everything is the reverse to get it back together.

 

Thanks!

Good thing I asked here first! I would have tightened the crap outta the fittings. Where would I obtain the necessary wrenches for the job?

Thanks for saving my butt!