The diesel injection pump is located at the right front side of the engine. In case of pump failure or damage, the pump must be replaced as an assembly, except for certain simple parts on the outside of the pump.
REMOVAL & INSTALLATION
- Disconnect the negative battery cable.
- Remove the air cleaner duct. Remove the engine under cover.
- Drain the engine coolant and then remove the radiator and its shroud.
- Loosen the fan pulley nuts, then remove the drive belts (air conditioning, alternator and power steering pump).
- Disconnect the power steering oil pump and position it out of the way.
- Tag and disconnect the accelerator wire, the overflow hose (on the spill tube side), the fuel cut solenoid connector and the fuel return hose.
- Tag and disconnect the potentiometer, the injection timing control solenoid valve wire, the cold start device water hoses (at the 4-way connector side) and the vacuum hoses for the vacuum modulator (automatic transmission models only).
- Remove the crank damper pulley. Use a plastic mallet and tap lightly around the sides. If this does not loosen the pulley you will need a two armed gear puller.
- Remove the pulley bracket and the idler pulley (if so equipped) and then remove the front dust cover.
- Loosen the spring set pin, set the tensioner pulley to the free tension position and then tighten them.
- Slide the injection pump drive belt off its pulleys.
- Loosen the retaining nut and remove the injection pump drive gear. You may need a two armed gear puller.
- Disconnect the injection tubes at the injection nozzle side.
- Unscrew the injection pump fixing nuts and the bracket bolt.
- Remove the injection pump assembly with the injection tubes attached.
If you plan to measure plunger lift, remove the injection tubes before removing the pump.
- Install the injection pump assembly and bracket in the correct position. Observe the following:
- Set the No. 1 cylinder at TDC of the compression stroke. Make sure that the grooves in the rear plate and the flywheel align and that the No. 1 cam lobe on the camshaft is in the position shown.
- Install the injection pump and temporarily tighten the mounting bolts.
- Use the alignment marks as shown in the illustration and install the injection pump drive gear. Tighten the nut to 43-51 ft. lbs. (59-69 Nm).
The injection pump drive shaft is tapered.
If the drive gear is difficult to install, use a plastic mallet and drive it into place.
- Make sure that the tensioner pulley is still in the free position and slide the injection drive belt over the pulleys.
- The drive belt should have two timing marks on it. Align one with the mark on the crank pulley and the other with the mark on the drive gear. If the timing marks on the drive belt are not clear enough to read, set the marks on the drive gear and the crank pulley so that there are 20 cogs of the drive belt between them when it is installed.
- Loosen the spring set pin and the tensioner so that the belt is automatically set to the tension position.
- Adjust the injection timing as detailed in this information.
- Tighten the injection pump nuts to 12-15 ft. lbs. (16-21 Nm) and the bracket bolt to 22-26 ft. lbs. (30-35 Nm).
- Reconnect the injection tubes. Connect them to the cylinders in this order: 4, 2, 6, 1, 5, 3.
- Bleed the air from the fuel system as detailed in this information.
- Install the idler pulley and bracket if so equipped. Install the crank damper pulley.
- Reconnect the potentiometer, the injection timing control solenoid valve wire, the cold start device water hoses (at the 4-way connector side) and the vacuum hoses to the vacuum modulator (automatic transmission models only).
- Connect the accelerator wire, the overflow hose (on the spill tube side), the fuel cut solenoid connector and the fuel return hose.
- Install the power steering oil pump and all drive belts. Adjust all drive belts to the correct tension.
- Install the radiator and shroud, refill the cooling system.
- Install the air cleaner duct and engine undercover. Reconnect the negative battery cable.
- Check all fluid levels, start the engine and inspect for any leaks. Road test the vehicle for proper operation.
INJECTION PUMP TIMING
- Remove the under cover and drain the coolant.
- Remove the coolant hoses that are connected to the cold start device.
- Remove the power steering pump.
- Set the No. 1 cylinder at TDC of its compression stroke. Make sure that the grooves in the rear plate and the drive plate are aligned with each other. Make sure that the No. 1 camshaft lobe is in the position shown in the illustration.
- Using two wrenches, remove the fuel injection tubes.
- Loosen the fork retaining screw on the cold start device. Turn the fork 90° and then set the cold start device in the free position.
Never remove the screw on the cold start device wire. If it should be removed accidentally, the pump assembly should be readjusted at a service shop specified by the manufacturer.
- Remove the plug bolt from the rear side of the injection pump and, in its place, attach a dial indicator.
- Loosen the injection pump mounting nuts and bracket bolt.
- Turn the crankshaft counterclockwise 15-20° from the No. 1 cylinder TDC position.
- Find the dial indicator needle rest point and set the gauge to zero.
- Turn the crankshaft clockwise two complete revolutions in order to remove the play in the camshaft mechanism. Loosen the tensioner and then retighten it.
- Turn the crankshaft clockwise until the No. 1 cylinder is again at TDC and then read the dial indicator.
- If the dial indicator is not within the above range, turn the injection pump counterclockwise to increase the reading and clockwise to decrease it.
- Tighten the injection pump mounting nuts and bracket bolt (torque figures are given in the preceding information).
- Remove the dial indicator and reinstall the plug bolt with a new washer. Tighten the plug bolt to 10-14 ft. lbs. (14-20 Nm).
- Set the fork at the cold start device in its original position by pulling on the cold start device wire and then tighten the fork screw.
- Connect the injection tubes.
- Install the power steering pump, connect the cold start device water hoses, refill with coolant and install the under cover.
BLEEDING THE FUEL SYSTEM
Air should be bled from the fuel system whenever the injection pump is removed or the fuel system is repaired.
- Loosen the priming pump vent screw and pump a few times. Make sure that the fuel overflows at the vent screw.
- Tighten the vent screw.
- Disconnect the fuel return hose and install a suitable hose over the overflow connector. Place a small pan under the overflow hose.
- Prime the priming pump to make sure that the fuel overflows at the open end of the hose.
- Remove the pan and the overflow hose and then install the return hose.