CLEANING AND INSPECTION

CLEANING

1. Insert a stiff nylon brush, ZTSE4320 , into the oil and fuel galleries of the supply manifold for cleaning.

2. Use compressed air to clean out debris from the oil galley.
INSPECTION FOR WARPAGE

Using a straightedge, OEM1293 , and feeler gauge, check the supply manifold gasket surface for warpage
utilizing the checking pattern shown in Figure 12.20 . Inspect for cracks.
SECTION 12: HIGH PRESSURE LUBE OIL SYSTEM

See new specifications at end of manual called "Specifications, Special Torque Values, and Service Tools".

HIGH PRESSURE LUBE OIL SYSTEM FLOW AND COMPONENTS

Refer to Figure 12.1 or 12.2 for a view of the lube oil system and its main components.

Figure 12.1 Front Mounted ICP Sensor

Figure 12.2 Mid Mounted ICP Sensor
HIGH PRESSURE PUMP

REMOVING THE INJECTION PRESSURE REGULATOR VALVE

NOTE: IT IS NOT NECESSARY to remove the injection pressure relief valve from the high pressure
pump, prior to removal of the pump. However, the solenoid, sleeve and tinnermann nut can be
removed for easy access to the high pressure pump mounting bolts.

Remove the Injection Pressure Regulator (IPR) valve as follows:

1. For engines with Serial Number 988150 and below. Disconnect the wiring harness from the IPR valve
( Figure 12.21 ).

2. For engines with Serial Number 988151 and up. Disconnect the wiring harness from the IPR valve
( Figure 12.22 ).
Figure 12.20 Checking Supply Manifold Gasket For Warpage

Figure 12.21 Engines Equipped With ICP Sensor Mounted In

The Three-Way Fitting
 Figure 12.22 Engines Equipped With ICP Sensor Mounted In
The Supply Manifold

3. Remove tinnermann nut securing solenoid to IPR valve. Remove sleeve and solenoid ( Figures 12.23 and
12.24 ).

4. Unscrew the IPR valve from the high pressure pump using a 28 mm (1-1/8 in.) deep wall socket ( Figure
12.25 )

Figure 12.23 Remove Tinnermann Nut

1. 1. Pump
2. 2. Tinnermann Nut
 Figure 12.24 Remove IPR Sleeve & Solenoid
1. 1. IPR Valve
2. 2. Solenoid
3. 3. Sleeve
 Figure 12.25 Remove IPR Valve
1. 1. Pump
2. 2. IPR Valve
REMOVAL

Use the following steps to remove the high pressure lube oil pump.

CAUTION:

BEFORE PERFORMING THIS PROCEDURE, BE SURE THE HIGH PRESSURE PUMP

RESERVOIR HAS BEEN DRAINED OF OIL. DRAIN THE RESERVOIR BY REMOVING THE
ENGINE OIL TEMPERATURE SENSOR (figure 12.26 ) FROM THE REAR HALF OF THE
FRONT COVER. EXTRACT OIL BY INSERTING THE TUBE FROM THE HAND OPERATED
VACUUM PUMP TOOL ZTSE2499 INTO THE COVER (FIGURE 12.27 ).

NOTE: IF THE IPR VALVE HAS NOT BEEN REMOVED, BE SURE THE IPR VALVE SOLENOID HAS BEEN
DISCONNECTED FROM THE MAIN WIRING HARNESS (FIGURE 12.21 or 12.22 ).

NOTE: BE SURE the lube oil supply hose has been disconnected, refer to "Supply Manifold Removal"
in this section, for the proper removal procedures.

1. Remove two (2) capscrews securing high pressure lube pump to front cover. Remove pump and gasket from
front cover

a. Figure 12.28 shows the high pressure pump on engines with serial number 988150 and below.
Figure 12.26 Removing Engine Oil Temperature Sensor From
High Pressure Oil Reservoir
Figure 12.27 Removing Oil From High Pressure Oil Reservoir

Figure 12.28 Remove High Pressure Oil Pump On Engines

S/N 988150 & Below

b. Figure 12.29 shows the high pressure pump on engines with serial number 988151 and up.
INSTALLATION

Use the following steps to install the high pressure lube oil pump.

1. On Engines With S/N 988150 & Below: Place new gasket onto high pressure pump and place the pigh
pressure pump into its location.

2. On Engines With S/N 988151 & Up: Install a new face seal into the groove of the front cover and place the
pigh pressure pump into its location.

3. Install two (2) capscrews and secure the high pressure pump to the front cover. Tighten the mounting bolts
to the special torque value ( Figures 12.29 ).

4. If removed, install IPR valve into the high pressure pump. Tighten valve to the special torque value ( Figure
12.30 ).

5. Install the IPR valve sleeve and solenoid to the IPR valve ( Figure 12.31 ).
Figure 12.29 Remove High Pressure Oil Pump On Engines
S/N 988151 & Up
 Figure 12.30 Install IPR Valve

Figure 12.31 Install IPR Sleeve & Solenoid

1. 1. IPR Valve
2. 2. Solenoid
3. 3. Sleeve
REMOVING AND INSTALLING SUPPLY MANIFOLD END PLUG

NOTE: THE SUPPLY MANIFOLD OIL RAIL MUST BE DRAINED PRIOR TO REMOVING THE FUEL
INJECTORS TO PREVENT LEAKAGE INTO THE CYLINDER BORE.

NOTE: BE SURE to clean any and all Loctite(r) from the end plug.

DRAIN SUPPLY MANIFOLD

1. Drain the supply manifold from the end plug of the supply manifold ( Figure 12.3 ).

NOTE: Be sure to clean any old Loctite(r) found on the threads of the plug prior to installation.

2. Install a new O-Ring and back-up ring onto the end plug.

3. Apply Loctite(r) #277 to the threads of the end plug and install into the supply manifold ( Figure 12.4 ).
Tighten plug to the special torque value ( Figure 12.5 ).
Figure 12.3 Removing Supply Manifold End Plug
 Figure 12.4 End Plug, O-Ring And Back-Up Ring Locations
1. 1. End Plug
2. 2. Back-up Ring
3. 3. O-Ring
Figure 12.5 Install Supply Manifold End Plug
SUPPLY MANIFOLD INSTALLATION

CONNECTION LOCATIONS AND INSTALLATION

Install and connect the supply manifold to the engine per the following steps:

CAUTION:

never place the supply manifold face down on a table or workbench. the flat surface finish of the manifold may scratch, prohibiting a seal
between the manifold and the crankcase.

NOTE: Install the supply manifold gasket with the tab stamped "FRONT", located on the lower left hand side of the gasket, facing the manifold assembly.

1. Place a new supply manifold gasket onto supply manifold (the gasket should have the tab located in the lower front corner for correct placement) ( Figure 12.33 ).

Figure 12.32 Installing Tinnermann Nut

1. 1. High Pressure Pump
2. 2. Tinnermann Nut

Figure 12.33 Installing Supply Manifold and Gasket To

 Cylinder Head
1. 1. Supply Manifold
2. 2. Supply Manifold Gasket

2. Install supply manifold to cylinder head and secure using twelve bolts. Tighten bolts to the special torque value.

Figure 12.34 shows an engine with the old style three-way fitting.

NOTE: WHEN TIGHTENING SUPPLY MANIFOLD BOLTS, BE SURE TO TIGHTEN FROM THE CENTER OUTWARD.

Figure 12.34 Installing Supply Manifold On Engines Equipped

With Old Three-Way Fitting

Figure 12.35 shows an engine with the new style three-way fitting.

Figure 12.35 Installing Supply Manifold On Engines Equipped

With New Three-Way Fitting

Figure 12.36 shows an engine with the engine mounted ECM unit.

Figure 12.36 Installing Supply Manifold On Engines Equipped

With Engine Mounted ECM Unit

3. Install the supply manifold end plug. Refer to "Removing and Installing Supply Manifold End Plug" , in this section.

4. Install the fuel return valve into the rear of the supply manifold ( Figure 12.37 ).
 Figure 12.37 Install Fuel Return Valve

5. Tighten fuel return valve to special torque value ( Figure 12.38 ).

6. Install banjo fitting to fuel return valve. Tighten to the special torque value ( Figure 12.39 ).

7. Install the fuel supply line and connect it from the fuel filter header to the front of the supply manifold. Tighten fitting to the special torque value.

a. Figure 12.40 shows the fuel supply line on engines equipped with the front mounted primer pump.

Figure 12.38 Tighten Fuel Return Valve

 Figure 12.39 Tighten Fuel Return Banjo Fitting

Figure 12.40 Install Fuel Supply Line On Engines Equipped

With Front Mounted Primer Pump
1. 1. Transfer Pump To Supply Manifold
2. 2. Transfer Pump To Fuel Filter Return
3. 3. Fuel Filter Header

b. Figure 12.41 shows the fuel supply line on engines equipped with top mounted primer pump.

c. Figure 12.42 shows the fuel supply line on engines equipped with the top mounted primer pump and the engine mounted ECM unit.
INSTALLING THE ICP SENSOR

Use one of the following procedures when installing the ICP Sensor.

Engines Equipped With The Old Three-Way Fitting

1. Apply Loctite(r) #277 to the threads of the ICP sensor.

2. Install the ICP sensor with a new O-Ring into the supply manifold elbow, located at the front of the
supply manifold. Tighten to the special torque value ( Figure 12.43 ).

Figure 12.41 Install Fuel Supply Line On Engines Equipped

With Top Mounted Primer Pump
Figure 12.42 Install Fuel Supply Line On Engines Equipped
With Engine Mounted ECM Unit
 Figure 12.43 Install ICP Sensor Into Old Three-Way Fitting

Engines Equipped With New Three-Way Fitting

1. Apply Loctite(r) #277 to the threads of the ICP sensor.

2. Install the ICP sensor with a new O-Ring into the supply manifold elbow, located at the front of the
supply manifold. Tighten to the special torque value ( Figure 12.44 ).

Engines Equipped With Engine Mounted ECM Unit

1. Apply Loctite(r) #277 to the threads of the ICP sensor.

2. Install the ICP sensor with a new O-Ring into center of the supply manifold elbow, located at the front
of the supply manifold. Tighten to the special torque value ( Figure 12.45 ).
INSTALLING THE LUBE OIL SUPPLY HOSE

Use one of the following steps to connect the high pressure pump lube oil supply hose to the pump and supply
manifold.

Engines Equipped With Old Three-Way Fitting

1. Install the hose to the high pressure pump and supply manifold. Tighten the nuts securing the hose to
the special torque value ( Figure 12.46 ).

Figure 12.44 Install ICP Sensor Into New Three-Way Fitting

 Figure 12.45 Install ICP Sensor Into Supply Manifold

Figure 12.46 Install Oil Supply Line On Engines Equipped

 With Old Three-Way Fitting
1. 1. High Pressure Pump
2. 2. Oil Supply Line Mounting Nuts
3. 3. Oil Supply Line

Engines Equipped With New Three-Way Fitting

1. Install the hose to the high pressure pump and supply manifold. Tighten the nuts securing the hose to
the special torque value ( Figure 12.47 ).

Engines Equipped With Engine Mounted ECM Unit

1. Install the hose to the high pressure pump and supply manifold. Tighten the nuts securing the hose to
the special torque value ( Figure 12.48 ).

Figure 12.47 Install Oil Supply Line On Engines Equipped

With New Three-Way Fitting
1. 1. Oil Supply Line Mounting Nuts
2. 2. Oil Supply Line
3. 3. High Oil Pressure Pump
 Figure 12.48 Install Oil Supply Line On Engines Equipped
With Engine Mounted ECM Unit
1. 1. Oil Supply Line Mounting Nuts
2. 2. Oil Supply Line
3. 3. High Oil Pressure Pump
SUPPLY MANIFOLD REMOVAL

DISCONNECT LOCATIONS AND REMOVAL

Disconnect the fuel supply line from the fuel filter header to the supply manifold:

1. Figure 12.6 shows the fuel supply line on engines equipped with the front mounted primer pump and old
three-way fitting.

a. Loosen and remove the hollow screws and copper sealing gaskets at the fuel filter header and supply
pump.

b. Cap the fuel filter header and supply pump openings.

2. Figure 12.7 shows the fuel supply line on engines equipped with the new three-way fitting and top mounted
primer pump.

a. Loosen fitting and remove fuel filter header to supply pump line.

b. Cap the fuel filter header and supply pump openings.

3. Figure 12.8 shows the fuel supply line on engines equipped with the top mounted primer pump and the
engine mounted ECM unit.

a. Loosen fitting and remove fuel filter header to supply pump line.

b. Cap the fuel filter header and supply pump openings.

Figure 12.6 Removing Fuel Line On Engines Equipped With

Old Three-Way Fitting
Figure 12.7 Removing Fuel Line On Engines Equipped With
New Three-Way Fitting

Figure 12.8 Removing Fuel Line On Engines Equipped With

Engine Mounted ECM Unit
REMOVING THE LUBE OIL SUPPLY HOSE

Engines Equipped With Old Three-Way Fitting

1. Loosen the nuts ( 2, Figure 12.9 ) and disconnect high pressure oil supply hose ( 3, Figure 12.9 ) from
the three-way fitting and the high pressure pump ( 1, Figure 12.9 ).

OR

Engines Equipped With New Three-Way Fitting

1. Loosen the nuts ( 1, Figure 12.10 ) and disconnect high pressure oil supply hose ( 2, Figure 12.10 )
from the three-way fitting and the high pressure pump ( 3, Figure 12.10 ).

OR
Figure 12.9 Removing Oil Supply Hose On Engines Equipped
With The Old Three-Way Fitting
1. 1. High Pressure Pump
2. 2. Oil Supply Line Mounting Nuts
3. 3. Oil Supply Line
 Figure 12.10 Removing Oil Supply Hose On Engines
Equipped With The New Three-Way Fitting
1. 1. Oil Supply Line Mounting Nuts
2. 2. Oil Supply Line
3. 3. High Oil Pressure Pump

Engines Equipped With Engine Mounted ECM Unit

1. Loosen the nuts ( 1, Figure 12.11 ) and disconnect high pressure oil supply hose ( 2, Figure 12.11 )
from the supply manifold and the high pressure pump ( 3, Figure 12.11 ).

2. Cap high pressure pump fittings and supply manifold fittings using high pressure oil cap set
ZTSE4295 .
REMOVING THE ICP SENSOR

Use one of the following procedures when removing the Injection Control Pressure Sensor.

Engines Equipped With Old Three-Way Fitting

1. Disconnect wiring harness, if not already done, and remove ICP sensor, together with O-Ring, from the
three-way fitting of the supply manifold ( Figure 12.12 ).

NOTE: Be sure to clean any and all old Loctite(r) found on the threads of the sensor prior to
installation.

Figure 12.11 Removing Oil Supply Hose From Engines

 Equipped With Engine Mounted ECM Unit
1. 1. Oil Supply Line Mounting Nuts
2. 2. Oil Supply Line
3. 3. High Oil Pressure Pump

Figure 12.12 Removing ICP Sensor From Old Three-Way

Fitting

Engines Equipped With New Three-Way Fitting

1. Disconnect the wiring harness, if not already done, and remove ICP sensor, together with O-Ring, from
the three-way fitting of the supply manifold ( Figure 12.13 ).

NOTE: Be sure to clean any and all old Loctite(r) found on the threads of the sensor prior to
installation.

Engines Equipped With Engine Mounted ECM Unit

1. Disconnect the wiring harness, if not already done and remove ICP sensor, together with O-Ring, from
the supply manifold ( Figure 12.14 ).

NOTE: Be sure to clean any and all old Loctite(r) found on the threads of the sensor prior to
installation.

2. Remove the banjo fitting at the fuel return valve, located at the rear of the supply manifold ( Figure
12.15 ).

Figure 12.13 Removing ICP Sensor From New Three-Way

Fitting
Figure 12.14 Removing ICP Sensor From Supply Manifold

Figure 12.15 Remove Banjo Fitting From Fuel Return Valve

3. Remove the fuel return valve from the supply manifold ( Figure 12.16 ).

4. If not already done, remove the supply manifold end plug. Refer to "Removing and Installing Supply
Manifold End Plug" , in this section.

NOTE: when the supply manifold is removed, do not place manifold face down on any surface.
the manifold face could be scratched, thus preventing a good mating surface seal. always place
supply manifold face up.

5. Remove twelve (12) mounting bolts securing the supply manifold to the cylinder head. Remove supply
manifold and gasket.

a. Figure 12.17 shows the supply manifold on an engine equipped with the old three-way fitting.

Figure 12.16 Remove Fuel Return Valve

 Figure 12.17 Removing Supply Manifold On Engines
Equipped With Old Three-Way Fitting

b. Figure 12.18 shows the supply manifold on an engine equipped with the new three-way fitting.

Figure 12.18 Removing Supply Manifold On Engines

Equipped With New Three-Way Fitting

c. Figure 12.19 shows the supply manifold on an engines equipped with the engine mounted ECM
unit.

Figure 12.19 Removing Supply Manifold On Engines

Equipped With Engine Mounted ECM Unit