HPOP Replacement - Riffraff Diesel

HPOP Replacement - Riffraff Diesel
HPOP Replacement
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IMPORTANT: Before starting installation, please be sure that all items
which were supplied with the kit are accounted for.
Recommended Parts:
-T500 HPOP With Gasket
-4 Fuel Line Sleeves (2-1/4”, 1-5/16”, 1-3/8”)
- IPR O-Ring Kit GZ-14-008
Recommended Tools:
-6595 HPOP Line Disconnect Tool
-Standard and Metric Sockets & Wrenches
-Vacuum pump
Instructions:
1) Remove both of the ground cables off of the batteries.
2) Remove the Power Stroke engine cover (If Installed)
using a 13 mm deep socket.
3) Drain the fuel bowl by placing a 3/8” hose over the
fuel drain tube. Open the drain lever on the fuel bowl
to allow the fuel to drain completely.
4) Remove the 3/16” Allen plug from the HPOP Reservoir
top. Insert a suitable hose into the reservoir and apply
vacuum to remove the reservoir oil. Draining the oil
now will reduce the mess later.
5) Remove the fuel lines from the fuel bowl. Remove the
(2) 1/4” lines on the passenger side using a 9/16”
wrench. The Return line is on the drivers side and is
5/8”, the feed line is also on the drivers side and is
3/4”. (Fig 1 & 2)
6) Remove the fuel bowl heater connector from the fuel
bowl. (Fig 3)
7) Remove the fuel drain valve sleeve off of the valve by
sliding aft to the drain tube.
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Fig 1
Fig 2
Fig 3
HPOP Replacement
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8) Remove the Exhaust Back Pressure Sensor (EBPS) using
a 9/16” wrench and a 1” wrench. Remove the EBPS
tube from the front cover nipple bracket using a 9/16”
and 5/8” wrench. (Fig 4)
9) Remove the fuel bowl attach bolts (2) using a 13 mm
socket. The fuel bowl will now be able to be removed
from the engine. (Fig 5)
10) Using the HPOP Line Release Tool, slide the tool in
between the hose flange and the rubber cover. This will
unlock the hoses from the fittings so you can remove
the hoses from the HPOP. (Fig 6)
11) Disconnect the Injector Pressure Regulator (IPR)
connector. Flip the wire bail up to unlock. (Fig 6)
12) Remove the front cover access plate by removing the
(2) bolts (8mm). The cover is sealed on with RTV, use
caution when removing it. (Fig 7)
13) Using an 18mm socket, loosen the bolt from the HPOP
Drive Gear. Be careful not to drop the washer in the
front cover. It may be necessary to hold the engine
from turning while loosening the drive gear bolt. (Fig 8)
14) Remove the (2) bolts (10mm) from the HPOP to the
front cover. You will now be able to remove the HPOP
from the engine. The drive gear will remain in the front
cover.
15) Place rags in the engine valley to absorb any oil.
16) Using a 1-1/8” wrench or special socket, remove the
IPR and install it in the new HPOP using new o-rings
(found in the GZ-14-008 kit). Tighten to 53 in-lbs.
17) Install the new HPOP and gasket , install the bolts but
do not torque fully yet. Align the HPOP drive gear onto
the pump shaft. The drive gear should be checked to
verify it is fully seated on the shaft before installing the
drive gear bolt and washer. Torque the bolt to 95 ft-lbs.
18) Torque the pump attach bolts (2) to 18 ft-lbs now.
Fig 4
Fig 5
Fig 6
Fig 7
Fig 8
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HPOP Replacement
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19) Attach the HPOP hoses to the HPOP. They will click
when installed fully and will not be able to be
removed. (Fig 9)
20) Install the IPR connector onto the IPR and secure the
wire clip.
21) Remove any rags in the engine valley.
22) Apply RTV to the drive gear access cover and install
the (2) bolts using a 8mm socket. Torque to 15-24 ftlbs. (Fig 7)
23) Install the fuel bowl into the valley. Position all of the
fuel lines (4) onto the fittings using new sealing
sleeves. (old sleeves can be removed with a 90o pick.
Just be careful you do not gouge the line). Start all four
lines onto the fittings, do not tighten fully. (Fig 10 &
11)
24) Insert the fuel bowl attachment bolts through the
HPOP reservoir and into the fuel bowl. Align the fuel
bowl where the bolts will engage the threads properly.
Tighten the bolts down to 18 ft-lb. (Fig 5)
25) Thread the EBPS tube onto the front cover nipple and
tighten the tube nut. (Fig 4)
26) Install the EBPS and reconnect the connector. (Fig 4)
27) Tighten the (4) fuel lines until the compression nut
touches the brass fitting. There should be no gap
between the fuel line nut and the fitting. (Fig 12)
28) Slide the fuel drain line sleeve over the fuel drain
valve. (Fig 6)
29) Install the fuel bowl heater connector. (Fig 3)
30) Close the fuel drain lever.
31) Pour in about 1 quart of diesel engine oil into the
HPOP reservoir to refill it (oil level should be about 1”
from the plug hole) and install the 3/16” plug.
Fig 9
Fig 10
Fig 11
Fig 12
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HPOP Replacement
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32) Reconnect the ground cables to the batteries.
33) Turn on the key to run (do not crank). Leave the key on 20-30 seconds and turn off.
Repeat this 2-3 times. This will allow the fuel bowl to replenish with fuel.
34) Check the fuel lines and bowl for any signs of leaks.
35) Check the engine oil to verify the level on the stick is correct.
36) Crank the engine over until it starts up. This may take several seconds to several
minutes depending on how much air is in the high pressure oil system. Do not
operate the starter for more than a minute at a time. For every minute of cranking,
allow two minutes of cool down time. Most engines will start within the initial
minute of cranking. If the truck fails to start, verify the oil level in the HPOP reservoir
and top off as required (reinstall the plug before cranking again). Having a battery
charger around will ensure the batteries remain fully charged during this process.
37) Once the engine starts it will run rough at first. Allow the engine to idle for a few
minutes. After a few minutes of normal idle, you can hold the idle at a high idle
setting (~ 1200 RPM). This will help move more oil through the system and help
purge air.
38) Check for fuel or oil leaks around all connections.
39) Install the Power Stroke Engine cover.
40) You will need to drive the truck for about 50 miles before all the air is purged and it
will begin to start normally (less cranking). ICP and IPR Duty Cycle will stabilize after
the 50 miles of driving also.
Special thanks to Ken (Woodnthings of FTE) for photos and instructions.
Disclaimer of Warranties and Liabilities
Riffraff Diesel disclaims any implied warranties of merchantability and fitness for a particular purpose.
Riffraff Diesel also disclaims any liability or consequential damages including, but not limited to,
repair labor, rental vehicles, hotel cost, or any other inconvenience costs.
This warranty is in lieu of all other warranties or guarantees, either expressed or implied, and shall not
extend to any consumer or to any person other than the original purchaser.
Toll Free Sales & Customer Service: (866) 446-3360
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