INSTRUCTIONS TO INSTALL INJECTION PUMP COVER
PLEASE READ AND UNDERSTAND THESE DIRECTIONS BEFORE STARTING INSTALLATION
1: REMOVE THROTTLE HOUSING THAT IS ABOVE INJECTION PUMP, USING A 13 MM WRENCH OR SOCKET. MOVE HOUSING OUT OF WAY BEING CAREFUL TO NOT PULL WIRES OUT OF THE APPS PLUG UNDERNEATH. YOU MAY REMOVE THE PLUG IF YOU WISH, BY PUSHING IN ON THE LOCK LEVER AND PULLING ON THE PLUG. YOU MAY WISH TO REMOVE THE INTAKE TUBE TOO FOR BETTER ACCESS USING A 10 MM SHALLOW SOCKET AND AN 11 MM (OR 7/16) DEEP SOCKET.
2: USING EITHER A #25 TORX BIT, OR A #25 TORX PLUS TAMPERPROOF BIT, DEPENDING ON WHICH KIND OF SCREWS YOU HAVE, REMOVE THE 5 RETAINING SCREWS ON THE METAL PUMP COVER.
3: REMOVE THE METAL COVER FROM TOP OF INJECTION PUMP AND BE SURE TO SAVE THE SMALL RECTANGULAR O-RING TYPE SEAL THAT FITS AROUND THE FOUR SOLDER CONNECTIONS. THIS SEAL MUST BE ON THE PUMP BEFORE INSTALLING THE NEW PLASTIC COVER.
4: UNSCREW THE ALLEN SCREW FROM THE PLASTIC COVER UNTIL THE SHARP POINT IS NOT PROTRUDING. PLACE COVER ON TOP OF PUMP AND BE SURE THE PLASTIC COVER IS IN ITS “HAPPY PLACE” AND ALL SCREWS ARE STARTED, BEFORE SNUGGING PLASTIC COVER DOWN TO TOP OF PUMP. DO NOT OVERTIGHTEN SCREWS.
5: TURN IN ALLEN SCREW, USING PROVIDED 1/16” ALLEN WRENCH, UNTIL RESISTANCE IS FELT AND TURN IN AN ADDITIONAL 3 ½ TURNS. CRIMP PROVIDED RING TERMINAL ONTO APPROPRIATE WIRE AND INSTALL OVER ALLEN SCREW. TIGHTEN LOCKNUT ON RING TERMINAL TO ONLY A MODERATE TENSION, TO PREVENT STRIPPING THE THREADS IN PLASTIC COVER.
6: REINSTALL THE THROTTLE HOUSING AND APPS PLUG IF YOU REMOVED IT. TO TEST CONNECTION OF THE PUMP WIRE TURN IGNITION SWITCH TO THE “ON” POSITION, WITHOUT STARTING TRUCK, AND VERIFY BATTERY VOLTAGE ON THE ALLEN SCREW. IF YOUR TRUCK ONLY IDLES WHEN YOU GET DONE, YOU PROBABLY FORGOT TO PLUG IN THE PLUG UNDER THE THROTTLE HOUSING
ADDITIONAL DIRECTIONS FOR BLUE CHIP FMS AND REDLINE PRODUCTS ONLY…..
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. USING A SINGLE EDGED RAZOR BLADE, CAREFULLY CUT AND REMOVE THE ELECTRICAL TAPE NEAR THE PLUG COVERING THE WIRES. LOCATE THE BLACK WIRE WITH A BROWN TRACER (NOT ALL BLACK). CONNECT THE BLACK WIRE FROM THE RED/BLACK HARNESS WITH THE FERRITE CORE IN IT, TO THE BLACK WIRE WITH A BROWN TRACER WITH THE SPECIAL “SCOTCHLOK” PROVIDED WITH BLUE CHIP PERFORMANCE PRODUCTS. RECONNECT THE PLUG TO THE PUMP BY STARTING WITH THE INDENTED PART OUT, OR IN THE RELEASED POSITION, AND PUSH THE PLUG IN TOWARDS THE PUMP WITH ONE HAND, UNTIL IT STOPS. THEN PUSH THE RETAINING LOCK TOWARD THE ENGINE WITH THE OTHER HAND. AFTER LOCK IS LATCHED TRY TO PULL CONNECTOR OFF PUMP. IF IT COMES OFF YOU DIDN’T GET THE LATCH STARTED CORRECTLY. PUSHING ON THE INDENTED LATCH SHOULD MOVE PLUG IN TOWARDS PUMP.
WE WILL NOT BE RESPONSIBLE FOR DAMAGED INJECTION PUMPS
Blue Chip Diesel Performance
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