Usage:
Disassemble Fuel Injection Pump Housing
start by:
a) remove fuel injection pump housing and governor as a unit
b) remove governor
c) remove shutoff control (if so equipped)
1. Remove governor drive housing (1) from fuel injection pump housing.
2. Remove plate assembly (2) from fuel injection pump housing.
3. Remove the cover (3) from side of housing.
4. Remove the cover (5). Remove the plug and seal (4) from housing.
5. Remove bolts and clamps that hold fuel injection pumps to the housing. Pull the pump bodies (6) straight up to remove them from housing.
6. Slide the end of each plunger out of the yoke in the lifter and pull out the plunger (7). Install the plunger in its respective pump body. Make identification on each of the fuel injection pumps by its location in the injection pump housing.
| NOTICE |
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Be very careful when removing fuel injection pumps to prevent damage to plunger surfaces. The body and plunger of each are put together at the factory and cannot be used with the bodies or plungers of other pumps. |
7. Remove the fuel rack (8) from housing.
8. Remove the three bolts (10) and locks that hold thrust plate. Remove the thrust plate (9).
9. Use wrench (A) to hold yoke screw (11). Loosen locknuts (12).
10. Remove yoke screws (11). Put identification on each yoke screw by its location in injection pump housing.
11. Install S1605 bolts (13) (3/8"-24 NF x 3 1/4" long) and needed washers in the lifters.
12. Tighten the bolts (13) enough to hold lifters away from the camshaft.
13. Remove the camshaft from housing.
| NOTICE |
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Be careful when removing the camshaft. Do not cause damage to camshaft or bearings. |
14. Remove the bolts (13) from the fuel pump lifters and remove lifters (14) and springs (15) from the bottom of the housing.
NOTE: Put identification on each of the lifters by its location in the housing.
15. Use tool group (B) to remove camshaft bearings from the housing.
16. Use tooling (C) to remove the bearings for fuel rack from the housing.
Assemble Fuel Injection Pump Housing
1. Use tooling (C) to install bearings for fuel rack in housing.
2. Use tool group (B) to install camshaft bearings. Be sure the oil holes (1) in bearings are in alignment with oil hole in housing.
| NOTICE |
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Be sure the tool group (B) is in center position on bearing while installing bearings, so no damage will be caused to them. |
3. Put clean engine oil on lifters (2). Install the lifters (2) in their respective position in housing.
4. Push the lifters in the housing against their springs.
5. Install S1605 bolts (3) (3/8"-24 NF x 3 1/4" long) and needed washers (4) in the lifters.
6. Tighten the bolts (3) enough to hold lifters up to install camshaft.
7. Put clean engine oil on the camshaft bearings.
8. Install the camshaft in the housing.
NOTE: If the engine has a counterclockwise rotation, the camshaft is installed with the arrow and the F-mark (5) at the front of pump housing as shown. For clockwise rotation of engine, the camshaft is installed with the F-mark and arrow at the rear of pump housing.
9. Remove the bolts and washers that were used to hold lifters up.
10. Install the thrust plate (6), locks and bolts that hold camshaft in housing.
11. Install yoke screws (7) and locknuts in their respective position in housing. Use wrench (A) to hold yoke screw while locknut is tightened.
12. Make adjustment to lifters. See FUEL PUMP TIMING DIMENSION SETTING (OFF ENGINE) in TESTING AND ADJUSTING.
13. Put clean diesel fuel on the fuel rack. Install the fuel rack (8) in the pump housing.
14. Install fuel injection pumps in their respective positions as follows:
a) Remove the plunger (9) from the pump (10) to be installed.
b) Put clean diesel fuel on the plunger and barrel of the pump.
c) Install the pump in housing. Turn the plunger until the mark (12) on gear is in alignment with mark on fuel rack (11).
d) Slide the end of plunger into the yoke screw of the lifter.
e) Install new seals for the pump and install the pumps in the housing.
NOTE: Be sure the pumps are on the dowels. Install the bolts and clamps.
f) Tighten the bolts next to fuel rack first, and then tighten bolts on other side. Tighten the bolts to a torque of 32 ± 5 lb. ft. (43 ± 7 N·m).
15. Install the plug and seal. Install the cover (13) for fuel rack.
16. Install plate (14) on side of pump housing.
17. Install governor drive housing (15) on the fuel injection pump housing.
18. Install plate assembly on pump housing.
end by:
a) install shutoff control (if so equipped)
b) install governor
c) install fuel injection pump housing and governor as a unit