Fuel Injection Pump Replacement

Fuel Injection Pump Replacement

REMOVAL
1. Disconnect negative battery terminal.
2. Remove throttle linkage.
3. Remove injection pump bracket.
4. Remove injection pump supply line from the injection pump.
5. Remove the high pressure supply lines that go to the injectors
6. Disconnect the solenoid electrical connector from the fuel solenoid.
7. Remove the air control tube.
8. Remove the injection pump vent line and cap screw.

CAUTION: The control lever is indexed to the control lever shaft during calibration. Do not remove the control lever from the injection pump.

9. Remove the injection pump support bracket.
10. Remove the oil filler tube bracket mounting screw and the oil filler tube and adapter from the engine front cover.

CAUTION: If the gear retainer nut or washer falls into the gear housing, the gear cover has to be removed to retrieve them before starting the engine.
11. Place a shop towel below the retainer nut in the gear housing cover opening to prevent the nut or washer from falling into the housing. Remove the gear retaining nut and washer.
12. Rotate the engine with the barring tool until the injection pump key-way is pointing directly down.
13. Slowly rotate the engine, with the barring tool, while pushing in on the timing pin. The pin will fall into a hole in the cam gear when the engine reaches Top Dead Center (TDC) of #1 cylinder. Stop rotating the engine once the timing pin drops into the cam gear.
14. Pull the timing pin out of the camshaft gear.

NOTE: Visually inspect the timing marks on the flange of the injection pump. Each pump and engine have unique timing marks. It is not possible to exchange pumps and use the same timing marks for alignment.

NOTE: All injection pumps have a lock-screw. The lock-screw is used to lock the injection pump shaft in place once TDC has been located. Rebuilt and new injection pumps should come with the shaft locked in place with the lock-screw.

15. Loosen the injection pump lock-screw. Remove the lock-screw washer and attach it to the injection pump flange with a piece of wire for use during installation.
16. Tighten the lock-screw

CAUTION: Make sure the injection pump key doesn't fall into the gear housing, because the gear cover would have to be removed to retrieve it before starting the engine.

17. Use a T-bar to pull the injection pump gear off the pump shaft. Use 8mm X 1.25mm screws to attach the T-bar to the shaft.
18. Remove the injection pump mounting nuts.
19. Remove the injection pump and clean the gasket surfaces on the engine block and the injection pump.