SERVICE MANUAL NUMBER 22 INJECTION PUMP

NOTE: If necessary, refer to SECTION 5E for description and location of electrical items.
22. Disconnect the Fuel Shut Off Solenoid wire.
23. Disconnect the Fuel Quantity Actuator/Sensor connector.
24. Disconnect the Fuel Timing Solenoid Valve connector.
25. Remove the three injection pump mounting nuts and washers.
26. Slowly turn central bolt of gear puller tool CLOCKWISE until pump and gear separate.
IMPORTANT: The injection pump shaft and gear use a key to stay in alignment. Be
careful not to drop the key into the engine when removing pump.
27. Paying special attention to the key, to avoid dropping it into the engine, carefully remove
the pump and place it aside.
IMPORTANT: Put suitable protective covers (shipping plugs or similar) over the
injection pump fuel ports to avoid contamination.
28. Back the central bolt out of the puller tool, but leave the tool installed.
IMPORTANT: Do NOT turn crankshaft after injection pump is removed. Battery cables
should remain disconnected and a notice attached to ignition switch to alert others
that the engine should not be disturbed.

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 INJECTION PUMP SERVICE MANUAL NUMBER 22

Fuel Injection Pump Installation

Installation With Engine Assembled
IMPORTANT: If engine has been disturbed, or must be rotated before installing
injection pump take care not to wedge pump gear in gear housing while turning
crankshaft.
1. Ensure cylinder number 1 piston is at top dead center (TDC) of its compression stroke
and timing marks are aligned.
1. Ensure pump gear is held in the same position as when pump was removed. This should
be cylinder number 1 TDC.
2. Rotate shaft to align keyway with cylinder number 1 injector port.
NOTE: To rotate shaft, temporarily install original shaft nut and a suitable jam nut. Do NOT
damage pump shaft threads with improper nuts or overtightening.

70420

Typical
a - Shaft Keyway

3. Remove any pump backlash by rotating shaft COUNTERCLOCKWISE (when facing

the pump) until resistance is felt.

b a

70421

b a
70767

Typical
a - Shaft - Rotate COUNTERCLOCKWISE
b - Keyway at 11 O clock

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 SERVICE MANUAL NUMBER 22 INJECTION PUMP

4. Being careful not to disturb shaft alignment, remove nuts temporarily installed to rotate
shaft.
5. Apply Perfect Seal sealant to a new injection pump gasket.
6. Install new gasket on pump mounting studs.
7. Ensure pump gear upper keyway is positioned approximately as shown.
c

a b
70768

a - Gasket
b - Pump Mounting Studs
c - Pump Gear Upper Keyway

8. Install injection pump key in pump shaft keyway. Apply heavy grease to hold key in
position.
9. Ensure the key is positioned properly.
IMPORTANT: Do NOT drop key into engine. If key is dropped into engine the key must
be removed before operation of the engine.
10. Insert pump shaft into gear, being careful not to dislodge key. Do NOT turn pump shaft
from 11 o clock position. Rotate pump body in slotted holes to align key with gear slot.
11. Install pump to cylinder block hex nuts with flat washers and lockwashers. Temporarily
only finger-tighten the nuts.
12. Remove gear puller tool. Make certain key is in position.
13. Using a new lockwasher, secure gear to shaft with hex nut. Torque nut to 88 Nm (64 lb-ft).
14. Using new O-ring in groove, install and securely tighten injection pump gear cover on
timing cover.

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 INJECTION PUMP SERVICE MANUAL NUMBER 22

15. Rotate pump to end of adjustment slot travel in direction shown.

70422

Typical
a - Direction To Rotate

16. Timing of the injection pump MUST BE accomplished. Refer to Fuel Injection Pump
Timing for instructions.

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 SERVICE MANUAL NUMBER 22 INJECTION PUMP

Installation During Engine Reassembly

1. Temporarily install crankshaft pulley, if removed previously.
2. Attach Crankshaft Tool 91-814827 if necessary.

CAUTION
To avoid severe engine damage the engine MUST BE set on cylinder number 1
COMPRESSION STROKE at Top Dead Center (TDC) before proceeding.
IMPORTANT: If crankshaft position was disturbed after assembly (rotated), it may be
necessary to slowly rotate the crankshaft, in the direction of rotation, numerous
revolutions to align the crankshaft gear, idler gear, and camshaft gear alignment
marks. Refer to SECTION 3A - Camshaft, and verify alignment to establish cylinder
number 1 Top Dead Center on compression stroke in the following steps.
3. Ensure cylinder number 1 piston is at TDC of its compression stroke and timing marks
are aligned.
4. Attach the graduated disc 91-801333500 to crankshaft with zero positioned as shown.
NOTE: Use the graduated disc adapter plate if crankshaft vibration damper is installed.

a 78198

d 70485
c
b 70419

Typical Engine
a - Adaptor Plate (To Damper, If Installed)
b - Bolts (3)
c - Graduated Disc
d - Crankshaft Tool

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 INJECTION PUMP SERVICE MANUAL NUMBER 22

5. Using a suitable gauge of wire, make a wire pointer. Attach the pointer to a suitable
location on the block. Do NOT damage the mating surfaces
6. Align wire pointer to zero degrees (0) as shown.

b 70419

a - Wire Pointer
b - Zero (0) Degree Mark

7. Using a heavy grease to hold key in place, install injection pump key in pump slot.
8. Temporarily install gear on injection pump shaft. Do NOT secure gear at this time.
9. Rotate shaft to align keyway with cylinder number 1 injector port.
10. Remove any pump backlash by rotating gear COUNTERCLOCKWISE (when facing
pump) until resistance is felt.
11. Ensure keyway is at approximately the 11 o clock position, as shown.

b a

70421

b a
70767

Typical
a - Shaft - Rotate COUNTERCLOCKWISE
b - Keyway at 11 O clock

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 SERVICE MANUAL NUMBER 22 INJECTION PUMP

12. Being careful not to disturb shaft alignment, remove gear. Ensure injection pump key
is properly positioned.
13. Apply Perfect Seal sealant to a new injection pump gasket.
14. Install new gasket on pump mounting studs.

a b
70768

a - Gasket
b - Pump Mounting Studs

15. Install pump to cylinder block.

16. Install hex nuts with flat washers and lockwashers. Temporarily only finger-tighten the
nuts.
17. Rotate pump to end of adjustment slot travel in direction shown.

70422

Typical
a - Hex Nuts With Flat Washers And Lockwashers (3 Total)
b - Direction to Rotate

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 INJECTION PUMP SERVICE MANUAL NUMBER 22

18. Ensure injection pump key is properly positioned.

IMPORTANT: Do NOT force gear on shaft.
19. Install gear on injection pump shaft, using whichever key slot on gear that allows gear
to be installed the easiest.
20. Using a new lockwasher, install gear on shaft with hex nut. Torque to 88 Nm (64 lb-ft).

a b

22217

70424

a - Gear
b - New Lockwasher
c - Hex Nut

21. Timing of the injection pump MUST BE accomplished. Refer to Fuel Injection Pump
Timing in this section for instructions.

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