Injection Pump Replace

Fig. 23 Crankcase Ventilation System:

Fig. 65 Fuel filter & lines:

REMOVAL
1. Disconnect battery ground cables and remove air cleaner assembly.
2. Remove crankcase ventilation filters and pipes from valve covers and air crossover, Fig. 23.
3. Remove air crossover, then install screened covers J-26996-2 or equivalent.
4. Disconnect throttle rod and throttle return spring.
5. Remove bellcrank.
6. Remove throttle and T.V. detent cables from intake manifold brackets and position aside.
7. Remove fuel lines to fuel filter, then the fuel filter and bracket, Fig. 65. If equipped with A/C, remove rear compressor base.
8. Disconnect fuel return line from injection pump.
9. To remove injection pump only:
a. Disconnect injection line clips.
b. Disconnect injection lines from injection pump and plug all open lines.
c. Reposition injection lines to gain access for pump removal.
d. Using tool J-26987, remove 3 pump retaining nuts, then remove pump.

Fig. 66 Fuel return lines. 1980 all & 1981 exc. Calif.:

Fig. 67 Injection nozzle installation. 1980 all & 1981 exc. Calif.:

Fig. 68 Injection nozzle installation. 1981 Calif. & all 1983---84:

10. To remove injection pump with injection lines attached:
a. On 1980 models and 1981 models except California, slide clamp from fuel return lines at injector nozzles, Fig. 66, and remove fuel return lines from each bank.
b. On all models, disconnect injection pump lines at injector nozzles, Figs. 67 and 68. It is necessary to use two wrenches.
c. Remove three nuts retaining injection pump with tool J-26987.
d. Remove injection pump and lines. Cap all lines and fittings.

Fig. 61 Fuel injection pump timing marks:

Fig. 69 Offset on fuel injection pump driven gear:

INSTALLATION
1. With cylinder No. 1 at TDC, align offset tang on pump driveshaft with pump driven gear, Fig. 69.
2. Install new pump to adapter O-ring, then install the pump or pump and lines, fully seating pump by hand. Loosely install 3 retaining nuts.
3. Align mark on injection pump with line on adapter, Fig. 61, then torque retaining nuts to 18 ft. lbs.

Fig. 65 Fuel filter & lines:

Fig. 66 Fuel return lines. 1980 all & 1981 exc. Calif.:

Fig. 67 Injection nozzle installation. 1980 all & 1981 exc. Calif.:

Fig. 68 Injection nozzle installation. 1981 Calif. & all 1983---84:

4. To install injection pump with injection lines attached:
a. Connect injector lines at injector nozzles. Using a back-up wrench on upper nozzle hex, torque line nuts to 25 ft. lbs., Figs. 67 and 68.
b. On 1980 (all) and 1981 except California, install fuel return lines to injectors on each bank, Fig. 66.
5. To install injection pump only:
a. Position injector lines in proper position and connect injector lines to injection pump. Torque line nuts to 25 ft. lbs.
b. Install injection line clips.
6. Connect fuel return line to injection pump.
7. Install fuel filter and bracket, then install fuel line. Return to Fig. 65, for torque specifications.
8. Install throttle and T.V. detent cables. Adjust T.V. cable.
9. Install bellcrank, then install throttle rod and throttle return spring. If equipped with A/C, install rear compressor brace.
10. Remove screened covers, then install air crossover.

Fig. 23 Crankcase Ventilation System:

11. Install crankcase ventilation filters and pipes to valve covers and air crossover, Fig. 23.
12. Install air cleaner assembly. Connect battery ground cables.
13. Start engine and allow to idle for several minutes. Turn ignition ``Off,'' for approximately two minutes, then restart to allow air to bleed off within pump.