Injection Pump In-Vehicle Service

FUEL INLET & RETURN PIPE GASKETS, REPLACE

1. Disconnect battery ground cable.
2. On models equipped with A/C, remove A/C compressor drive belt, then unfasten compressor and position aside.
3. On all models, if removing fuel inlet hose, disconnect hose, then remove fuel inlet pipe and gaskets. If removing fuel return hose, disconnect hose, then remove fuel return pipe and gaskets.
4. Replace gaskets, then reverse procedure to install.

TACHOMETER PLUG O-RING, REPLACE

1. Disconnect battery ground cable.
2. On models equipped with A/C, remove A/C compressor drive belt, then unfasten compressor and position aside.
3. On all models, remove ``Tach'' plug and replace O-ring.
4. Reverse procedure to install. Torque ``Tach'' plug to 8 ft. lbs.

Fig. 37 High pressure plug removal:

HIGH PRESSURE PLUG O-RING, REPLACE

1. Disconnect battery ground cable.
2. On models equipped with A/C, remove A/C compressor drive belt, then unfasten compressor and position aside.
3. On all models, remove fuel injection lines as an assembly.
4. Remove high pressure plug using tool J-33309, Fig. 37. Remove O-ring.
5. Reverse procedure to install. Torque high pressure plug to 50 ft. lbs.

Fig. 38 Delivery valve removal:

DELIVERY VALVE HOLDER GASKET, REPLACE

1. Disconnect battery ground cable.
2. If equipped with air conditioning, remove A/C belt, then compressor and position aside.
3. Remove fuel injection lines as an assembly.
4. Using a suitable 14 mm wrench, remove delivery valve holder(s), Fig. 38.
5. Remove delivery valve and seat assembly. The delivery valve and seat assembly are match ground and should not be interchanged with other delivery valve and seat assemblies.The letters A, B, C, & D are engraved on each cylinder of the distributor head. Remove each delivery valve in proper sequence to ensure correct assembly.
6. Remove delivery valve gasket.
7. Reverse procedure to install. Torque delivery valve holder(s) to 28 ft. lbs.




MAXIMUM FUEL ADJUSTMENT SCREW/LOAD SCREW O-RING, REPLACE

1. Disconnect battery ground cable.
2. On models equipped with A/C, remove A/C compressor drive belt, then unfasten compressor and position aside.
3. On all models, remove fuel return hose and pipe.
4. Remove staking wire, then disconnect accelerator cable.
5. Install an M8 x 1 jam nut against adjusting screw locknut. Tighten the two nuts together to preserve adjustment.
6. Remove full load adjusting screw, then O-ring.
7. Install new O-ring.
8. Reverse procedure to install. Torque full load adjusting screw locknut to 6 ft. lbs. and remove jam nut.