Usage:
Start By:
a. remove fuel injection lines
1. Disconnect four fuel lines (1).
2. Disconnect connector (2).
3. Disconnect two fuel lines (4).
4. Remove wire (5).
5. Disconnect two connectors (3).
6. Disconnect hose (6).
7. Disconnect four connectors (7).
8. Remove two bolts (8).
9. Remove eleven bolts (11).
10. Remove bracket (9) and cover (10) together.
11. Remove four bolts (14) and spacer (12). At assembly, torque bolts (14) to 230 ± 15 N·m (170 ± 11 lb ft).
12. Remove drive gear assembly (13).
13. Remove three bolts (15).
14. Remove bolt (16).
15. Remove bracket (17).
16. Remove tube (18).
17. Remove three bolts (21).
18. Remove bolt (20) and bracket (19).
19. Attach a hoist to pump (22) as shown. Remove the pump. The weight of the pump is 91 kg (200 lb).
NOTE: Reverse the order of Steps 1 thru 19 for installation.
20. Time the fuel injection pump.
NOTE: For timing of the fuel injection pump, see the topic /bq/Install Automatic Timing Advance/eq/ in this module.
End By:
a. install fuel injection lines
Disassemble Governor & Fuel Injection Pump Housing
Start By:
a. remove fuel transfer pump
b. remove governor and fuel injection pump housing
1. Remove five bolts and washers (1), cover (2) and the gasket.
2. Disconnect receptacle (3).
3. Put identification marks on wires (4) for assembly. Use Tool (B) to disconnect wires (4).
4. Remove three bolts and washers (6), bracket assembly (5), electronic control (7) and the gasket.
5. Remove five bolts and washers (8), housing assembly (9) and the gasket from fuel injection pump housing (10).
6. Remove two bolts, one clip and two clamps (12).
7. Remove solenoid (11) and the seal from housing assembly (9).
8. Remove shutoff solenoid (13) with Tool (E) and the seal.
9. Remove receptacle (3) from clip assembly (14).
10. Remove two bolts and washers (15) and clip assembly (14).
11. Remove lever group (16) from housing assembly (9).
12. If necessary, remove spring (17) from lever group (16).
13. Loosen jam nut (18).
14. Remove control group (19) from housing assembly (9). If necessary, remove the O-ring seal.
15. Remove spring (20) from control group (19).
16. Remove retaining ring (21) and shaft (22).
17. If necessary, remove retaining ring (23) and lip-type seal (24).
18. If necessary, remove spring (25).
19. Remove four bolts (26), rotary servo group (27) and the gasket from fuel injection pump housing (10).
20. Remove two bolts (28), cover (29) and the gasket.
21. Remove spring (30) and valve (31) from rotary servo body.
22. Remove bolt (32) and body assembly (33).
23. Remove three O-rings (34) and shaft assembly (35).
24. Separate shaft (39) from star gears (36) and (37).
25. Remove key (38) if necessary.
26. Remove sensor (42).
27. Remove bolts (40) and drive housing (41).
28. Remove tube assembly (43).
29. Remove bolt and washer (44). Remove rack control bar (45).
30. Remove two bolts (46) and servo piston assembly (47).
31. Remove retaining ring (48), spring seat (49), link spring (50), rack control sleeve (51) and ring (52) from servo piston assembly (47).
32. Remove sleeve (55), piston (54) and valve (53) from servo piston assembly (47). Remove the O-ring seal from sleeve (55).
33. Remove two bolts (56) and pump drive gear (57).
34. Remove the bolt and plug (61) and rack link (60).
35. Remove two bolts (59), support assembly (58) and the pin.
36. Remove the washers. Use Tool (A) to remove twelve bushings (62) and the seals.
37. Install Tool (D) in the pump housing with the square end down (end with taper will be up). Hold the racks against Tool (D) and remove each of fuel injection pumps (63) with Tool (B). For more detail, see the topic, "Remove Fuel Injection Pumps" in this module.
NOTE: Mark pumps (63) so they may be returned to their original location at assembly.
38. Mark for identification at assembly right and left hand rack regulators (64). Remove both rack regulators.
39. Remove six bolts (65), two bolts (66), the plate assembly and the gasket from fuel injection pump housing (10).
40. Remove bypass valve (67) and the O-ring seal. If necessary, press out adapter (68).
41. Remove bypass valve assembly (69) from valve body (73).
42. Remove O-ring seal (70) from bypass valve assembly (69).
43. Remove spring (71) and bypass valve (72) from housing (73).
44. Use a seal pick to remove valve lifters (74) and the spacers. Put identification on each of the spacers and lifters as to their location in the pump housing.
45. Remove two bolts (75) and the locking tabs.
46. Remove camshaft lock (76).
| NOTICE |
|---|
Be careful not to damage the camshaft bearings as the camshaft is removed. |
47. Remove camshaft (77) from fuel injection pump housing (10).
48. If necessary, use Tool (C) to remove camshaft bearings (78).
49. If necessary, remove fourteen bolts (79), the cover and the gasket from each side of fuel injection pump (10).
Assemble Governor & Fuel Injection Pump Housing
1. If removed, install camshaft bearings (78) with Tool (C). See the Specifications Form No. SENR4651 for proper location and orientation of the bearings.
2. If removed, install fourteen bolts (79), the cover and the gasket to each side if fuel injection pump (10). Tighten bolts (79) to 14 ± 4 N·m (10 ± 3 lb ft).
3. Install camshaft (77) to fuel injection pump housing (10).
4. Install camshaft lock (76).
5. Install two bolts (75) and the locking tabs.
6. Put clean engine oil on lifters (74). Install lifters (74) and the spacers in their original locations.
7. Coat O-ring seal (70) with clean engine oil. Install O-ring (70) to bypass valve assembly (69).
8. Install spring (71) and bypass valve (72) to valve body (73).
9. Install bypass valve assembly (69) to housing (73).
10. Coat the O-ring seal with clean engine oil. Install the O-ring seal and bypass valve (67). If removed, press in adapter (68).
NOTE: Coat the O-ring seal with clean engine oil.
11. Install the gasket, plate assembly, six bolts (65) and two bolts (66) to fuel injection pump housing (10).
12. Put clean engine oil on two rack regulators (64). Install right and left hand rack regulators (64) in their proper locations.
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If one or more of the injection pumps have been installed wrong, damage to the engine is possible if cautions are not taken when the engine is first started. Make preparation to close off the air intake to stop the engine if necessary. |
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13. Use Tool (B) to install fuel injection pumps (63) and the spacers in their original location. For more detail see the topic "Install Fuel Injection Pumps".
14. Install bushing (62) and the seal in the pump housing bore. If the injection pump is in the correct position, bushing (62) will turn into the threads of the pump housing with the fingers until it is even with the housing. Use Tool (A) to tighten bushing (62) to a torque of 245 ± 15 N·m (180 ± 10 lb ft). Install the washers.
15. Check the rack movement (travel) with Tool (E) after each pump is installed. See the topic "Injection Pump Installation" in Testing & Adjusting.
16. Repeat Steps 13 thru 16 for the remaining pumps and bushings.
17. Install rack link (60), plug (61) and the bolt.
18. Install both Tools (D) and hold the racks against the pins
19. Rotate plug (61) to equalize bank to bank rack setting, then tighten bolt.
20. Install the pin, support assembly (58) and two bolts (59).
21. Install pump drive gear (57) and two bolts (56).
22. Install the O-ring seal on sleeve (55). Install valve (53), piston (54) and sleeve (55) in servo piston assembly (47).
NOTE: Lubricate the seal and the cylinder with clean engine oil prior to assembly. Assemble with the sleeve and the cylinder aligned as shown.
23. Install retaining ring (48), spring seat (49), link spring (50), rack control sleeve (51) and ring (52) to servo piston assembly (47).
24. Install two bolts (46) and servo piston assembly (47).
25. Install tube (43).
26. Install rack control bar (45). Install bolt and washer (44).
27. Install bolts (40) and drive housing (41).
28. Install sensor (42).
29. Adjust the gap between sensor (42) and gear (54) to 0.76 ± 0.15 mm (.030 ± .006 in). Tighten the nut on sensor (42) to a torque of 14 ± 1 N·m (10 ± 1 lb ft).
30. Install shaft (39) to star gears (36) and (37).
31. Install key (38).
32. Install three O-rings (34) and shaft assembly (35).
33. Install spring (30) and valve (31) to rotary servo body.
34. Install bolt (32) and body assembly (33).
35. Install two bolts (28), cover (29) and the gasket.
36. Install four bolts (26), rotary servo group (27) and the gasket to fuel injection pump housing (10).
37. If removed, install spring (25).
38. If removed, lubricate lip-type seal (24) lightly with clean engine oil. Install lip-type seal (24) and retaining ring (23).
39. Install shaft (22) and retaining ring (21).
40. Install spring (20) to control group (19).
41. If removed, install the O-ring seal. Install control group (19) to housing assembly (9).
42. Install and tighten jam nut (18) to 55 ± 7 N·m (41 ± 5 lb ft).
NOTE: With rack pinned at "zero" position adjust sensor output as required. With timing pin in timing hole in fuel pump housing and timing slot in camshaft and No. 1 cylinder at top center, compression stroke static timing is 19.5 BTC.
43. If removed, install spring (17) to lever assembly (16).
44. Install lever assembly (16) to housing assembly (9).
45. Install receptacle (3) to clip assembly (14).
46. Install two bolts (15) and clip assembly (14).
47. Use Tool (G) to install the seal and shutoff solenoid (13). Lubricate the seal lightly with glycerin. Tighten solenoid assembly (13) to 70 ± 10 N·m (50 ± 7 lb ft).
48. Install solenoid (11) and the seal to housing assembly (9). Lubricate the seal lightly with glycerin.
| NOTICE |
|---|
Make sure the lever on the solenoid engages correctly in the sleeve on the rack servo. If the lever is not engaged in the sleeve the engine may run too fast or may fail to start. |
49. Install two bolts, one clip and clamps (12).
50. Install five bolts (8), housing assembly (9) and a new gasket to fuel injection pump housing (10).
51. Install three bolts and washers (6), bracket assembly (5), electronic control (7) and the gasket.
52. Connect receptacle (3).
53. Identify marks on wires (4) for assembly. Connect wires (4).
54. Install cover (2) and a new gasket with five bolts (1).
55. Make an adjustment to the fuel rack setting. See the topic "Governor-Fuel Rack Setting" in Testing & Adjusting.
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If assembly is not correct, damage to the engine is possible if cautions are not taken when the engine is first started. Make preparation to close off the air intake to stop the engine if necessary. |
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End By:
a. install governor and fuel injection pump housing
b. install fuel transfer pump