Diesel MFI Pump: Service and Repair

- remove drive belt guard for injection pump sprocket

- turn crankshaft to TDC on cyl. #1
- markings: flywheel/clutch housing, injection pump/sprocket must align (arrows)





- lock injection pump sprocket with pin
- secure injection pump sprocket with locking wrench
- loosen mounting screws and remove sprocket with drive belt
- loosen mounting nut for injection pump approximately one turn and then remove pin





- apply tension to injection pump sprocket with puller
- hit puller spindle head (arrow) with light hammer taps until sprocket loosens from injection pump tapered shaft
- remove mounting nuts and remove injection pump sprocket
- disconnect fuel feed and return lines, lines for shut-off, and accelerator cable





- use open end box wrench to loosen injector lines
- unscrew mounting bolts for the injection pump from the mounting bracket and support
- remove pump

Installation





- mount injection pump so that markings on injection pump flange align with those on mounting bracket (see arrows)
- insert mounting bolts and tighten slightly
- adjust rear support such that it rests against cylinder block and injection pump, free of tension
- tighten securely
- mount injection pump sprocket ana turn so markings on sprocket and mounting bracket align (arrows)
- lock sprocket with pin and tighten mounting nut specification 45 Nm (33 ft lb)
- mount drive belt with sprocket for injection pump
- just tighten sprocket mounting bolt enough to allow sprocket to turn by hand
- check drive belt tension, adjust if necessary
- check that TDC marking on flywheel aligns with reference mark
- secure sprocket for the injection pump with a locking wrench and tighten
^ specification 100 Nm (74 ft lb)
- remove pin 2064





- release tension on cable for cold start acceleration by loosening screw (1) on bracket; and by turning bracket 90°

NOTE: Screw (2) must not be loosened.





- connect adapter and small dial gauge (range 0 to 3mm) with approximately 2.5mm (0.098 in.) pre.tension (in place of the sealing screw)

NOTE: Always replace the gasket for the sealing screw

- tightening torque - 15 Nm (11 ft lb), if there is leaking re-tighten to a maximum of 25 Nm (18 ft lb)
- slowly turn crankshaft (opposite to engine rotation) until dial gauge no longer moves
- adjust dial gauge with approximately 1mm (0.039 in.) of pretension to "0"
- turn crankshaft (direction of engine rotation) until TDC marking on flywheel aligns with reference mark
- read delivery rate on dial gauge
- check valve: 0.81 - 0.95mm (0.070 - 0.232 in.) stroke
- adjusting valve: 0.88 ± 0.02mm (0.346 ± 0008 in.)

NOTE: If the check valve lies within the specified tolerance, a new adjustment is NOT necessary.

NOTE: Misadjustment can be corrected by loosening the mounting screws on the mounting bracket and support, then turning the pump.

- tighten injection pump mounting screws to 25 Nm (18 ft lb)
- connect injector line, fuel feed and return lines, line for shut off and accelerator cable
- union screws and injector lines torque: 25 Nm (18 ft lb)

CAUTION: Do not interchange the union screws for the injector lines. Union screws for the return line have a valve, and are identified by "OUT" on top of the hex head.





NOTE: On fuel injection pumps which are replacement parts, the manifold pressure compensator housing is sealed. After installing the pump, the housing must be opened as follows.

If pump has ventilation hose (1)
- remove sealing clamp (arrow)

If pump has rubber cap (2)
- cut off tip of rubber cap so opening for ventilation is free (arrow)

- install drive belt guard
- adjust idle and maximum RPM