Diesel MFI Pump: Service and Repair

Fig. 14 Injection pump removal:

REMOVAL

1. Disconnect ground cables from both batteries.
2. Remove engine cooling fan and fan shroud.
3. Remove A/C compressor and/or power steering pump drive belt and idler pulley, if equipped.
4. Remove injection pump drive gear cover and gasket.
5. Rotate crankshaft until injection pump drive gear keyway is at top dead center position.
6. Remove large nut and washer from pump drive gear. Use care to avoid dropping washer into timing gear case.
7. Disconnect air intake hose from intake manifold and air cleaner.
8. Disconnect throttle cable and speed control cable, if equipped.
9. Disconnect and cap fuel inlet line at injection pump.
10. Disconnect fuel shut-off solenoid electrical connector from injection pump.
11. Remove fuel injection lines. Cap lines and fittings.
12. Disconnect lower fuel return line from injection pump and fuel lines.
13. Loosen lower No. 3 intake port nut and remove fuel return line.
14. Remove injection pump attaching nuts and bolt, Fig. 14.
15. Disconnect cold start cable, then remove injection pump using a suitable puller. Use care to avoid dropping key into timing gear case when removing pump.

INSTALLATION

1. Connect cold start cable, then install injection pump in timing gear case, aligning key with keyway in drive gear in top dead center position.
2. Install injection pump attaching nuts and bolt and tighten sufficiently to draw pump into position.
3. Install pump drive gear washer and nut and torque to 40 ft. lbs.
4. Install injection pump gear cover with a new gasket.
5. Adjust pump timing as described under ``Injection Pump Timing.''
6. Install all fuel lines and clamps.
7. Connect fuel shut-off solenoid electrical connector.
8. Connect throttle cable and speed control cable, if equipped.
9. Bleed fuel system as follows:
a. Loosen air vent plug on fuel filter.
b. Operate priming pump on top of fuel filter adapter until clear, bubble-free fuel flows from vent plug.
c. Close vent plug while holding priming plug in fully depressed position.
d. Disconnect fuel return line from injection pump.
e. Operate priming pump until fuel flows from return port on injection pump.
f. Reconnect fuel return line to injection pump, then run engine and check for leaks.
10. Install air intake hose, drive belt and idler pulley.
11. Install engine cooling fan and fan shroud, then reconnect battery ground cables.