DESCRIPTION
A Robert Bosch high-pressure CP3 fuel injection pump is used. The CP3 pump is attached to the back at the timing gear housing at the left ftront side of the engine.

OPERATION
The CP3 fuel injection pump supplies high pressure to the fuel rail independent of engine speed. This high pressure is then accumulated in the fuel rail. High-pressure fuel is constantly supplied to the injectors by the fuel rail. The Engine Control Module (ECM) controls the fueling and timing of the engine by actuating the injectors. Fuel enters the system from the electric fuel transfer (lift) pump, which is located in the fuel tank. Fuel is forced through the fuel filter element and then enters the Fuel Pump/Gear Pump. which is attached to the rear of the CP3 fuel injection pump. The Fuel Pump/Gear Pump is a low-pressure pump and produces a minimum pressure of 440 kpa (64psi). Fuel then enters the CP3 fuel injection pump. Low-pressure fuel is then supplied to the FCA (Fuel Control Actuator).

The FCA is an electronically controlled solenoid valve. The ECM controls the amount of fuel that enters the high-pressure pumping chambers by opening and closing the FCA based on a demanded fuel pressure. The FPS (Fuel Pressure Sensor) on the fuel rail provides the actual fuel pressure. When the actuator is opened, the maximum amount of fuel is being supplied to the CP3 fuel injection pump. Any fuel that does not enter the injection pump is directed to the cascade overflow valve. The cascade overflow valve regulates how much excess fuel is used for lubrication of the pump and how much is returned to the tank through the drain manifold. Fuel entering the injection pump is pressurized to between 200-1800 bar (2901 - 26107 psi) by three radial pumping chambers. The pressurized fuel is then supplied to the fuel rail.

REMOVAL

CAUTION: Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines and CP3 fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This, in turn, could lead to a possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only.

1. Disconnect both negative battery cables at both batteries. Cover and isolate ends of both cables.
2. Remove intake manifold air intake tube (above injection pump) and its rubber connector hose.
3. Remove accessory drive belt.

4. Thoroughly clean rear of injection pump, and attachment points for its fuel lines. Also clean the opposite ends of these same lines at their attachment points.
5. Disconnect quick-connect fitting by pressing on button.
CAUTION: Whenever a fuel line fitting is connected to. a secondary fitting, always use a backup wrench on the secondary fitting. Do not allow the secondary fitting to rotate.
6. Remove high-pressure fuel line to fuel rail.
7. Remove banjo bolt.
8. Disconnect FCA (Fuel Control Actuator) electrical connector.
9. Remove line clamp.

10. Remove fuel pump drive gear access cover with a 3/8" drive ratchet. Access cover is threaded to timing gear cover.
11. Remove fuel pump drive gear mounting nut and washer.
12. Attach C3428B, or L4407A (or equivalent) gear puller to pump drive gear with 2 bolts, and separate gear from pump (a keyway is not used on this particular injection pump). Leave drive gear hanging loose within timing gear cover.

13. Remove three injection pump mounting nuts (6), and remove pump from engine.

INSTALLATION

1. Inspect pump mounting surfaces at pump and mounting flange and pilot bore for nicks, cuts or damage. Inspect O-ring surfaces for nicks, cuts or damage.
2. Clean injection pump mounting flange and pilot bore at gear housing. Also clean front of injection pump.
3. Install new rubber O-ring (square) into machined groove at pump mounting area.
4. Apply clean engine oil to injection pump O-ring and pilot bore only. The machined tapers on both injection pump shaft and injection pump gear must be absolutely dry, clean and free of any dirt or oil film. This will ensure proper gear-to-shaft tightening.
5. Clean pump gear and pump shaft at machined tapers with an evaporative type cleaner such as brake cleaner.
6. FUEL INJECTION PUMP PHASING: Perform the following phasing procedure anytime the injection pump has been removed and re-installed.

7. Locate the end of the fuel injection pump shaft. Two numbers (750 and 0) are stamped into the end of the shaft.

8. Rotate the injection pump shaft until the number 5 (located in the center of number 750) is positioned at 9 o'clock.
9. Position injection pump to mounting flange on gear housing while aligning injection pump shaft through back of injection pump gear. Be sure the number 5 is still at the 9 o'clock position.
10. Bring the engine to TOe position. Do this by rotating the crankshaft until the TDe mark on the crankshaft damper is at 12 o'clock position. It does not matter if cylinder #1 or #6 is at top. Again, check to be sure the number 5 is still at the 9 o'clock position. Rotate pump shaft accordingly.

11. After pump is positioned flat to mounting flange, install three pump mounting nuts and tighten finger tight
only. Do not attempt a final tightening at this time. Do not attempt to tighten (pull) pump to gear housing
using mounting nuts. Damage to pump or gear housing may occur. The pump must be positioned flat to
its mounting flange before attempting to tighten three mounting nuts.
12. To prevent damage or cracking of components. install and tighten nuts in the following sequence:
a. Install injection pump shaft washer and nut to pump shaft. Tighten nut finger tight only
b. Do preliminary (light) tightening of injection pump shaft nut (1).
c. Tighten three injection pump mounting nuts to 24 N·m (18 ft. Ibs.).
d. Do a final tightening of pump shaft nut to 105 N·m (77 ft. Ibs.).
13. Install drive gear access cover using a 3/8" drive ratchet. Access cover is threaded to timing gear cover. Tighten to 8 N·m (71 in. Ibs.) torque.

14. Install fuel return line. Tighten banjo bolt  to 24 N·m (18 ft. Ibs.) torque.
15. Install quick-connect fitting.
16. Install fuel line (injection pump-to-fuel rail). Using a back up wrench, tighten fitting at fuel pump to 40 N·m (30 ft. Ibs.) torque. Tighten fitting at fuel
rail to 40 N·m (30 ft. Ibs.) torque.
17. Install clamp.
18. Connect Fuel Control Actuator (FCA) electrical connector to rear of injection pump.
19. Install rubber intake manifold air intake tube. Tighten clamps .
20. Install accessory drive belt.
21. Connect both negative battery cables to both batteries.
22. Check system for fuel or engine oil leaks.

DESCRIPTION
The Fuel Control Actuator (FCA) (3) is located at the rear of the high-pressure, fuel injection pump.

OPERATION
The Fuel Control Actuator (FCA) is an electronically controlled solenoid valve. The ECM controls the amount of fuel that enters the high-pressure pumping chambers by opening and closing the FCA based on a demanded fuel pressure. When the FCA is opened, the maximum amount of fuel is being supplied to the fuel injection pump. Any fuel that does not enter the injection pump is directed to the cascade overflow valve. The cascade overflow valve regulates how much excess fuel is used for lubrication of the pump and how much is returned to the fuel tank through the drain manifold. An audible click from the FCA is normal when operating the key from the ON to the OFF position.

REMOVAL
1. Remove electrical connector (6) from Fuel Control Actuator (FCA).
2. Remove FCA mounting screws (1).
3. Twist and pull FCA to remove from injection pump.

INSTALLATION
1. Lubricate new Fuel Control Actuator (FCA) O-ring with clean oil before installation.
2. Turn FCA in a clockwise direction while pressing it into machined bore on rear of fuel injection pump. Be sure FCA flange is flush with the mounting surface on fuel injection pump.
3. Install FCA mounting screws (1) by hand.
4. Tighten FCA mounting screws (1) to 7 N·m (62 in.
Ibs).

Parts needed / Part number

1. 68197867AB fuel Filter

2. 68157291AA Water separtor

3. 29mm socket f or the fuel filter cap

4. ratchet / extensions / elbows 

5. oil filter rubber wrench is helpful for the water seperator

Filter Locations

Filter 1 is on the driver side of the engine mounted to the block. You will need a 29mm socket to undo this.  You will also likely need a elbow or 2 to get around the hood cowl.  Note the cap is plastic so take care not to strip it.  

Filter 2 is located just in front of the Rear Axel centered above the drive shaft.  This filter is a screw on filter.  

** please note that you will get a good amount of fuel spillage when you unscrew this filter.  Ensure your eyes are not going to be leaked on.  

Note the water in fuel sensor / drain.  this sensor can be unplugged from the truck harness to make removal easier.  

The Part number for this is PFRK54553  but you dont need to replace unless damaged.  a new o-ring comes with the filter.

The fuel heater is used to prevent diesel fuel from waxing during cold weather operation. When the fuel temperature is below 45° ±8 F (7°C), the temperature sensor allows current to flow to the heater element warming the fuel. When the fuel temperature is above 75 0 ±8 F (24°C), the sensor stops current flow to the heater element. Battery voltage to operate the fuel heater element is supplied from the ignition switch and through a solid stated device in the TIPM. The fuel heater element and "solid state device in TIPM" are not computer controlled.The heater element operates on 12 volts, 300 watts at 0° F (-18° C).

DIAGNOSIS AND TESTING

FUEL HEATER
The fuel heater is used to prevent diesel fuel from waxing during cold weather operation.

NOTE: The fuel heater element, "solid state device in TIPM" is not controlled by the Engine Control Module (ECM).

A malfunctioning fuel heater can cause a wax build-up in the fuel filter/water separator. Wax build-up in the filter/separator can cause engine starting problems and prevent the engine from revving up. It can also cause blue or white fog-like exhaust. If the heater is not operating in cold temperatures, the engine may not operate due to fuel waxing.

The fuel heater assembly is located on the side of the fuel filter housing and internal to the fuel filter housing. The heater assembly is equipped with a built-in fuel temperature sensor (thermostat) that senses fuel temperature. When fuel temperature drops below 45° ± 8° F (7° C), the sensor allows current to flow to the built-in heater element to warm fuel. When fuel temperature rises above 75 o± 8° F (24° C), the sensor stops current flow to heater element ( the circuit is open). Voltage to operate fuel heater element is supplied from the ignition switch, though solid state device in TIPM, to fuel
temperature sensor and on to fuel heater element. The heater element operates on 12 volts, 300 watts at 0 OF (-18° C). As temperature increases, power requirements decrease. A minimum of 7 volts is required to operate the fuel heater. The resistance value of the heater element is less than 1 ohm (cold) and up to 1000 ohms warm.

TESTING
1. Disconnect the electrical connector from the heater element. Ambient temperature must be below the circuit close temperature. If necessary, induce this ambient temperature by placing ice packs on a thermostat to produce an effective ambient temperature below circuit close temperature. Measure resistance across two pins. Operating range is 0.3 - 0.45 Ohms.
2. If resistance is out of range, replace heater element.

If you happen to notice your grid heater light is on while your driving this is a sign of injector failure. The ECM has the ability to detect excessive return flow from the injectors. Grid heater light is a warning to the owner that the injectors are worn out and all six injectors should be replaced very soon. 

A certain amount of air becomes trapped in the fuel system when fuel system components on the supply and/or high-pressure side are serviced or replaced. Fuel system priming is accomplished using the electric fuel transfer (lift) pump.

Servicing or replacing fuel system components will not require fuel system priming. The fuel transfer (lift) pump is self-priming: When the key is first turned on (without cranking engine), the pump operates for approximately 1 to 2 second and then shuts off (Note: When ambient temperatures are cold enough to cause the intake air heaters to operate, the fuel lift pump will operate during the entire intake air pre-heat cycle). The pump will also operate for up to 25 seconds after the starter is quickly engaged, and then disengaged without allowing the engine to start. The pump shuts off immediately if the key is on and the engine stops running.

1. Turn the key to CRANK position and quickly release the key to ON position before engine starts. This will operate fuel transfer pump for approximately 25 seconds.

2. Crank engine. If the engine does not start after 25 seconds, turn the key to OFF position, and leave it off for at least 5 seconds. Repeat the previous step until the engine starts.
3. Fuel system priming is now completed.
4. Attempt to start the engine. If the engine will not start, proceed to following steps. When the engine does start, it may run erratically and be noisy for a few minutes. This is a normal condition.

CAUTION: Do not engage the starter motor for more than 30 seconds at a time. Allow two minutes between cranking intervals.
5. Perform previous fuel priming procedure steps using fuel transfer pump. Be sure fuel is present at the fuel tank.
6. Crank the engine for 30 seconds at a time to allow fuel system to prime.

WARNING: The fuel injection pump supplies extremely high fuel pressure to each individual injector through the high-pressure lines. Fuel under this amount of pressure can penetrate the skin and cause personal injury. Wear safety goggles and adequate protective clothing. Do not loosen fuel fittings while the engine is running.