Chevrolet Chevette/1000 1976-1988 Repair Guide

Injection Pump

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REMOVAL & INSTALLATION





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Fig. Fig. 1Exploded view of the diesel injection pump linkage. Note the location of the idle adjusting screw and the fast idle adjuster (knurled nut)



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Fig. Fig. 2The tension spring is located behind the front plate beside the injection pump on the diesel engine



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Fig. Fig. 3Use a lockbolt to ensure the index marks on the injection pump gear and the front plate stay in alignment

This procedure will require the use of two special tools: a gear puller (J-22888) and a fixing plate (J-29761). It is a long and complicated procedure and must be performed in conjunction with the following injection timing procedure. We do not suggest that the average amateur mechanic perform these procedures.

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system. Remove the fan shroud, radiator and coolant recovery tank.
  4.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Disconnect the bypass hose leading from the front cover and then remove the upper half of the front cover.
  2.  

Fan removal may facilitate better access to certain front cover retaining bolts.

  1. Loosen the timing belt tension pulley and plate bolts. Slide the tensioner over.
  2.  
  3. Unscrew the two retaining bolts and remove tension spring from behind the front plate, by the injection pump.
  4.  
  5. Remove the injection pump gear retaining nut and then remove the gear with a gear puller.
  6.  
  7. Tag and disconnect any wires, hoses or cables leading from the pump. Disconnect and plug the fuel feed lines.
  8.  
  9. Remove the fuel filter. Disconnect the injector lines at the pump and at the injector nozzles and remove the lin