Isuzu C-240PW-28 - Fuel Injection Pump Removal and Installation

ARMY TM 9-2815-254-24
AIR FORCE TO 38G1-94-2
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Remove caps/plugs and install new washers (12 and 13, FIGURE 3-4) in each injector port.
Install each fuel injector (11) and temporarity tighten them. Final tightening will be done after fuel tubes are
connected.
Remove caps and position fuel tubes (1, 2, 3, and 4) between fuel injection pump and their respective fuel
injector (11). Tighten sleeve nuts on each end evenly a little at a time, to reduce undue stress on the tubes,
to 27 ft-lbs (36.6 Nm).
An improperly positioned clamp assembly (5) will result in objectionable
fuel pulsing noise and possible fuel tube rupture.
Carefully position and tighten each of the three clamp assemblies (5).
Tighten fuel injector screw (22) to 54 ft-lbs (73.2 Nm).
Remove caps and position fuel tube (10) on each fuel injector (11) and at fuel filter. Secure to fuel fitter with
fluid passage bolt (8) and two new seals (9). Secure to each fuel injector (11) with fluid passage bolt (6) and
two new seals (7). Tighten each fluid passage bolt to 132 in-lbs (14.9 Nm)
Bleed engine fuel system, refer to paragraph 3-12.
Operate engine and check for leaks and proper operation.
3-11. FUEL INJECTION PUMP.
3-11.1.
Removal.
a. Drain engine cooling and lubrication systems. Refer to end item maintenance manual.
Fuel is flammable. Keep fuel away from heat and open flame. Failure
to observe this warning could result in serious personal injury or death.
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