Injection Pump

REMOVAL & INSTALLATION

WARNING
After the pump is reinstalled, the injection timing must be reset. Adjusting the injection timing requires special tools for measuring the prestroke of the pump. If these tools are not available, do NOT remove the injection pump or attempt to work on it.

1. Disconnect the battery ground cable.
2. Remove the upper cover from the timing belt.
3. Remove the nut and washer holding the injection pump sprocket to its shaft.

   NOTE: Be careful not to drop the nut and/or washer into the lower timing cover.

4. Turn the crankshaft to bring the No.1 piston to TDC/compression. When the piston is in this position, all the timing marks align.
5. Use a pulley puller or extractor to carefully remove the injection pump sprocket. Catch the small Woodruff key and don't lose it.

   Fig. 1: The diesel fuel injection system and component locations

   WARNING
   Do not subject the shaft to impact. Protect the timing belt from any stress, twisting or fluids. After the sprocket is removed, do not turn the crankshaft.

6. Disconnect the boost compensator hose at the injector pump.
7. Remove the vacuum hose from the vacuum regulating valve and the injection pump.
8. Disconnect the electrical harness running to the pump.
9. Wrap the joints with rags or cloth and remove the fuel supply hose and the return hose from the injection pump and plug the ports immediately. Fuel will be released when these joints are opened.
10. Loosen the union nuts and remove the injection lines. Use a second wrench to counterhold fittings where possible.
11. Remove the two mounting bolts, then remove the mounting nuts and washers.

    NOTE: The pump is heavy and awkward to hold; make sure you or a helper have a firm grip before releasing the mounts.

    WARNING
    Do not hold the pump by either the accelerator lever or the fast idle lever. Additionally, these levers must not be removed from the pump. The levers' adjustment and placement is critical to the correct operation of the pump.

12. Remove the injection pump mounting bracket from the engine.
13. Before reinstalling the pump, make certain the entire pump is clean and the lines have been checked for dirt and foreign matter.
14. Install the mounting bracket on the engine and tighten the bolts to 26 ft. lbs. (35 Nm).
15. Carefully mount the pump and tighten the nuts and bolts to 19 ft. lbs. (26 Nm).
16. Install the fuel delivery lines. Counterhold the joint while tightening the line fittings to 22 ft. lbs.(29 Nm).
17. Carefully connect the the fuel supply hose and the return hose to the pump.
18. Connect the wiring harness to the pump.
19. Install the vacuum hoses between the regulating valve and the injection pump.
20. Connect the boost compensator hose and connect the negative battery cable.
21. Carefully install the sprocket on the shaft of the injection pump. Do not subject the shaft to impact and do not damage the timing belt. Make sure the Woodruff key is correctly seated in its groove.
22. Perform the ignition timing adjustment procedure outlined in this section.

    WARNING
    This adjustment MUST be performed each time the injection pump is removed.

23. Bleed the fuel system.
24. Install the upper timing belt cover.