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Old 10-21-2009, 03:23 PM   #1 (permalink)
GOBLUESIXFIVE
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injection pump

So im getting ready to replace the injection pump on my 97 K2500 with the 6.5. Has anyone replaced one on this engine and if so do u have a step by step instructions on what to do. Im replacing it myself and i am pretty tool savy but i wondered if anyone could give me some help or pointers thanks.
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1997 Cheverolet K2500 Ext cab. Straightpipe exhaust.
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Old 10-22-2009, 06:10 PM   #2 (permalink)
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Anyone????????
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1997 Cheverolet K2500 Ext cab. Straightpipe exhaust.
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Old 10-22-2009, 06:47 PM   #3 (permalink)
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There are no step-by-step instructions on here as far as I know. Although, there was a thread a few weeks ago that contained links to 6.5 rebuild manuals from the military. They might give instructions on how to do it.
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Old 10-23-2009, 01:41 AM   #4 (permalink)
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any pointers anyone can give at least?
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Old 10-23-2009, 02:12 AM   #5 (permalink)
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I sent you this list in chat, but here it is for future reference .

Removal:
  1. Disconnect batteries. Remove intake manifold. Remove fuel injection lines.
  2. Disconnect wiring, fuel return line, and fuel supply line from injection pump. Cap all fuel line openings. Remove A/C hose retainer bracket (if equipped). Remove oil filler tube and vent hose assembly. Remove grommet.
  3. Scribe an alignment mark on front cover and injection pump flange. Remove injection pump gear-to-injection pump bolts, accessible through oil filler neck hole (rotate crankshaft as necessary). Remove injection pump mounting nuts. Remove injection pump and gasket.
Install:
  1. Install injection pump gasket. Install injection pump, aligning locating pin on injection pump hub with slot in injection pump gear. Loosely install injection pump mounting nuts.
  2. Align timing marks on injection pump flange and front cover. Tighten pump mounting nuts to specification. Install injection pump gear-to-injection pump bolts. Tighten bolts to specification.
  3. To complete installation, reverse removal procedure. Ensure fuel lines are properly connected to ports on the injection pump. Diagram Here
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Old 10-23-2009, 02:19 AM   #6 (permalink)
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Pick up wrench, click it to counter clockwise, and get started

If you run into any issues, or just need some reassurance, we're gonna be right here

Remember, tape between the socket and IP gear bolts to help grab the bolt so it won't fall into the front cover... Then you have a REAL job on your hands

Crows foot wrenches might be a good investment for the injector lines. When undoing them, go top to bottom, and when reinstalling them, go bottom to top, so you have the most clearance for your wrench to get on the collars.

All the normal hand tools worked fine for me though.

Might be worth your while to make some sort of bench/dock that you can lean over that'll bring you to hood level, and allow you to be comfy, you'll be there a while lol the rad support isn't the most comfortable thing to lean over for a long period of time, trust me.

Good luck!
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Old 10-23-2009, 08:14 AM   #7 (permalink)
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Quote:
Originally Posted by WhiteK2500 View Post
Might be worth your while to make some sort of bench/dock that you can lean over that'll bring you to hood level, and allow you to be comfy, you'll be there a while lol the rad support isn't the most comfortable thing to lean over for a long period of time, trust me.

Good luck!
Agreed. the hood latch hurts after a very short while of being in your gut, leg, where-ever.

To the OP, make sure you number the injection lines in the firing order, as to not mess up their locations. I did this and had no issue figuring out which lines went to what cylinder when it was re-install time. In fact the tape and numbering is still all there, under the intake manifold.
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Old 10-23-2009, 08:26 AM   #8 (permalink)
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DS4 Injection Pump R&R - Some Tips
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Old 10-26-2009, 10:44 PM   #9 (permalink)
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thanks alot for that post guys i really need the help lol
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Old 10-28-2009, 03:36 PM   #10 (permalink)
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thanks alot guys for the help and info ima start tearing it down right now and ill let u know how it goes
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