Injection Pump Replace

Fig. 29 Front cover to injection pump timing mark:

When installing injection pump on California models, ensure half circles align to form a complete circle. Any deviation in timing will result in the two half circles not matching. If a new injection pump is being installed, use the conventional timing marks, Fig. 29.

Fig. 30 Injection pump drive gear bolt removal:

VAN
Removal
1. Remove intake manifold. Refer to ``Intake Manifold, Replace.''
2. Rotate air cleaner snorkel up to gain clearance.
3. Remove hood latch, then the windshield washer bottle.
4. Remove upper fan shroud.
5. Remove oil fill tube and grommet.
6. Working through oil fill tube hole, remove injection pump drive gear bolts, Fig. 30. It may be necessary to rotate engine to gain access to injection pump drive gear bolts.
7. Remove fuel filter, bracket and injection pump feed line.
8. Disconnect wire looms from injection lines.
9. Disconnect fuel injection lines from brackets, then remove engine oil dipstick.
10. Disconnect injection pump electrical connectors.
11. Disconnect T.V. cable (if equipped).
12. Disconnect throttle cable.
13. On 1982---85 models, proceed as follows:
a. Disconnect injection lines 2, 4, 5, 6, 7 and 8.
b. Raise and support vehicle.
c. Disconnect injection lines 1 and 3.
d. Cap injectors and lines to prevent entry of dirt.
e. Identify injection lines at pump and remove. Cap line and pump openings.
14. On 1986---87 models, disconnect injection lines.
15. On all models, disconnect fuel return line.
16. Scribe a mark on front cover and pump flange to aid during reassembly.
17. Remove injection pump retaining bolts, then remove injection pump.

Fig. 29 Front cover to injection pump timing mark:

Fig. 31 Injection pump locating pin:

Fig. 32 Injection pump installation:

Installation
1. Install new gasket. Align locating pin on pump hub with slot in injection pump gear, Fig. 31. Align scribe mark on front cover and pump flange, then torque attaching nuts to 35 ft. lbs. on 1982---85 models, or 30 ft. lbs. on 1986---87 models, Figs. 29 and 32.
2. Install pump driven gear into injection pump and torque bolts to 20 ft. lbs.
3. Reverse remaining removal procedure to install.