Diesel Injection Pump, Removing and Installing

DIESEL INJECTION PUMP, REMOVING AND INSTALLING

Removing





- Rotate crankshaft to TDC for No. 1 cylinder (arrow).
- Lock camshaft with setting
- Centralizing the setting bar:
Turn camshaft so that one end of the setting bar contacts the cylinder head. Using a feeler gauge, measure the gap at the other end of the setting bar. Place a feeler gauge equal to half that gap between the setting bar and cylinder head. Turn camshaft until the setting bar contacts the feeler gauge. Place a 2nd feeler gauge, of the same thickness, at the other end between the setting bar and the cylinder head.
- Remove the toothed belt from the camshaft and injection pump sprockets.
- Remove injection pump sprocket mounting nut.





- Loosen the puller arms and raise them up.
- Insert the puller arms through the injection pump holes in the sprocket and tighten.
- Put the injection pump sprocket under tension using the puller.
- Release injection pump sprocket from injection pump taper by tapping on spindle of puller (arrow) (then hold the sprocket so that it doesn't fall off).
- Remove all fuel lines from pump and cover openings with clean cloth.

CAUTION: Fire hazard. Do NOT smoke or have anything in the area that can ignite Diesel fuel.

NOTE: Use 3035 open wrench to remove high pressure fuel lines.

- Remove engine shut-off cable.
- Detach accelerator and Cold Start Accelerator cable.





- Remove mounting bolts from console (arrows).





- Remove bolt from rear support (arrow).

NOTE: Do NOT loosen the injection pump head mounting bolts. Loosening these bolts sideloads the head and will cause the distributor plungers to fracture.

Installing
- Install injection pump and align to center position in the flange elongated holes.
Tightening torque:
Mounting bolts: 25 Nm (18 ft lb)
Fuel lines: 25 Nm (18 ft lb)
Injection pump sprocket: 45 Nm (33 ft lb)

NOTE: Do not interchange the fuel supply and return line banjo bolts. The return line banjo bolt has a smaller internal diameter and "OUT" is marked on the hexagon head.





- Install injection pump sprocket and lock in position using pin 2064.
- Loosen the camshaft sprocket securing bolt 1/2 turn. Release camshaft sprocket from camshaft taper by tapping with a hammer (using a drift through rear toothed belt guard opening).
- Ensure that the TDC mark on flywheel and the reference mark are aligned.
- Install toothed belt and remove injection pump sprocket locating pin.





- Tension toothed belts (turn tensioner with pin wrench e.g. Matra V159 (arrow) to right).
Scale value: 12-13
as measured between camshaft sprocket and injection pump sprocket.
- Tighten camshaft sprocket securing bolt to 45 Nm (33 ft lb).
- Remove setting bar.
- Turn crankshaft two complete rotations in direction of engine rotation and again check toothed belt tension.
- Check injection timing
- Check idle speed and governed speed.