INSTRUCTIONS TO INSTALL INJECTION PUMP COVER

PLEASE READ AND UNDERSTAND THESE DIRECTIONS BEFORE STARTING INSTALLATION

FOR BLUE CHIP PRODUCTS FOLLOW ALL DIRECTIONS.  FOR COMPETITORS’ FOLLOW 1-5 ONLY  


1: REMOVE THROTTLE HOUSING, USING 13 MM WRENCH OR SOCKET. MOVE HOUSING OUT OF WAY BEING CAREFUL TO NOT PULL OUT WIRES UNDERNEATH, GOING TO THROTTLE POSITION SENSOR. YOU MAY WISH TO REMOVE THE INTAKE TUBE TOO FOR BETTER ACCESS. TO DO THIS YOU WILL NEED A 10 MM SHALLOW AND AN 11 MM (OR 7/16) DEEP SOCKET.


2: USING EITHER A #25 TORX  OR A #25 TORX PLUS TAMPERPROOF, DEPENDING ON WHICH KIND OF SCREWS YOU HAVE, REMOVE THE 5 RETAINING SCREWS ON THE PUMP COVER.


3:REMOVE THE METAL COVER FROM TOP OF INJECTION PUMP AND BE SURE TO SAVE THE SMALL O-RING TYPE SEAL THAT FITS AROUND THE FOUR SOLDER CONNECTIONS. THIS SEAL MUST BE ON THE PUMP BEFORE INSTALLING THE NEW COVER.


4: UNSCREW THE ALLEN SCREW FROM THE PLASTIC COVER AND PLACE COVER ON TOP OF PUMP. BE SURE THE COVER IS IN ITS “HAPPY PLACE,” AND ALL SCREWS ARE STARTED, BEFORE SNUGGING COVER DOWN TO TOP OF PUMP. DO NOT OVERTIGHTEN SCREWS.


5: TURN IN ALLEN SCREW, USING A 1/16” ALLEN WRENCH UNTIL RESISTANCE IS FELT AND TURN AN ADDITIONAL 3 ½ TURNS. TIGHTEN LOCKNUT ON RING TERMINAL TO A MODERATE TENSION, AS IT IS POSSIBLE TO STRIP THE THREADS FROM THE PLASTIC COVER. TO TEST THE CONNECTION, BE SURE THE THROTTLE POSITION SENSOR IS STILL PLUGGED IN UNDER THE THROTTLE HOUSING, TURN THE IGNITION ON AND VERIFY THAT THERE IS BATTERY VOLTAGE ON THE ALLEN SCREW.


6: REMOVE THE MAIN HARNESS PLUG AT THE BACK OF THE PUMP. TO REMOVE PLUG FIND INDENT ON SIDE OF PLUG CLOSEST TO THE FENDER AND PULL IT AWAY FROM THE WIRES OR TOWARD THE FENDER. TO MAKE THIS EASIER, USE THE OTHER HAND AND PULL OR WIGGLE THE PLUG TOWARD THE FIREWALL AT THE SAME TIME. WITH A SINGLE EDGED RAZOR BLADE CUT THE ELECTRICAL TAPE NEAR THE PLUG AND PEEL BACK THE PLASTIC COVERING. CUT BLACK ELECTICAL TAPE ON WIRES TO GAIN ACCESS TO THE WIRES UNDERNEATH. LOCATE THE BLACK WIRE WITH A BROWN TRACER (NOT ALL BLACK) AND FASTEN THE BLACK WIRE FROM THE RED/BLACK PIGTAIL TO THIS WIRE WITH THE SCOTCHLOK PROVIDED WITH BLUE CHIP PERFORMANCE PRODUCTS. RECONNECT THE PLUG TO THE PUMP BY STARTING WITH THE INDENTED PART OUT (RELEASED POSITION), AND PUSH THE PLUG IN TOWARDS THE PUMP WHILE PUSHING THE RETAINING LOCK TOWARD THE ENGINE. TRY TO PULL CONNECTOR OFF PUMP AND IF IT COMES OFF YOU DIDN’T GET THE LATCH STARTED CORRECTLY. PUSHING ON THE INDENTED LATCH SHOULD MOVE PLUG IN TOWARDS PUMP.

7: INSTALL THE THROTTLE HOUSING, MAKING SURE YOU HAVEN'T PULLED ON THE THROTTLE POSITION WIRES AND THERFORE DISCONNECTED OR LOOSENED THEM. IF YOUR TRUCK ONLY IDLES WHEN YOU GET DONE, YOU NEED TO FIX THE CONNECTION OF THESE WIRES.

WE WILL NOT BE RESPONSIBLE FOR DAMAGED INJECTION PUMPS
Blue Chip Diesel Performance
PO Box 339
East  Derry NH 03041
888-472-7373