Usage:
preparatory steps:
a) remove fuel transfer pump
b) remove fuel injection lines
1. Rotate the crankshaft to top dead center compression stroke No. 1 piston. See LOCATING TOP DEAD CENTER COMPRESSION POSITION FOR NO. 1 PISTON in TESTING AND ADJUSTING.
2. Remove variable timing unit cover (1). Remove drive gear, retainer, mounting bolts, and lock.
3. Disconnect the governor control linkage from governor. Remove the governor control channel assembly (2).
4. Remove the turbocharger heat shield water outlet line (3).
5. Remove the fuel ratio control sensing line (4). Remove the governor-to-right aftercooler housing mounting bracket (5). Remove the two governor-to-bracket mounting bolts (6) from the rear of governor. Disconnect wiring from shutoff solenoid.
6. Disconnect the fuel inlet line and fuel return line from the fuel injection pump housing and from the fuel filter housing. Move these lines away from the fuel injection pump housing.
7. Remove the fuel filter housing bleed line clamp mounting bolt (9) from the front of right aftercooler housing. Remove the water temperature shutoff sending unit (10).
8. Remove the fuel injection pump housing oil drain elbow (11).
9. Remove the five fuel injection pump housing mounting bolts (7) and bracket (8).
NOTE: Observe the location of the two ground body mounting bolts. Install these bolts back in their original location when installing the fuel injection pump housing.
10. Attach a hoist and move the assembly forward to clear O-ring seals at rear of housing. Remove the fuel injection pump housing and governor as a unit - weight 190 lbs. (86 kg).
Install Fuel Injection Pump Housing And Governor As A Unit
1. Attach a hoist and position the fuel injection pump housing and governor on the engine. Move the assembly toward the rear of engine to seat the O-ring seals in cylinder block.
2. Install the five fuel injection pump housing mounting bolts and bracket. Make sure the ground body bolts are installed in their original locations.
3. Install the fuel injection pump housing oil drain elbow.
4. Install the water temperature shutoff sending unit. Install the fuel filter housing bleed line clamp mounting bolt.
5. Connect the fuel injection pump housing fuel inlet and fuel return lines to pump housing and to the fuel filter housing.
6. Install the two governor bracket mounting bolts in rear of governor. Install the governor-to-right aftercooler housing mounting bracket. Install the fuel ratio control sensing line.
7. Install the turbocharger heat shield water outlet line.
8. Install the governor control channel assembly. Connect the governor control linkage to the governor.
9. Install the variable timing unit drive gear, retainer, mounting bolts, and lock. Do not tighten the mounting bolts.
10. Time the fuel injection pump camshaft to engine. See FUEL INJECTION PUMP CAMSHAFT TIMING in TESTING AND ADJUSTING.
11. Install the variable timing unit cover.
12. Remove the timing pins from inlet camshaft and from fuel injection pump camshaft. Install the timing pins in their respective storage positions. Install the right valve cover.
concluding steps:
a) install fuel injection lines
b) install fuel transfer pump
Disassemble Fuel Injection Pump Housing
preparatory steps:
a) remove fuel injection pump housing and governor as a unit
b) remove governor
c) remove variable timing unit
1. Remove the timing pin assembly from its storage position. Install one of the pin retaining bolts upside down through one of the flange holes. Install the pin assembly into timing hole and move rack back and forth slowly until the timing pin engages slot in rack. Depress timing pin until head of inverted bolt (1) touches housing.
| NOTICE |
|---|
Do not attempt to remove fuel injection pumps if rack is not positioned as outlined above. |
2. Remove the fuel transfer pump-to-fuel injection pump housing adapter housing (2).
3. Identify each of the fuel injection pumps by its location in the fuel injection pump housing. Remove the pump mounting bolts. Pull straight up on each pump to remove it from housing.
4. Disassemble the fuel injection pumps as follows: Using wrench (A), remove the retainer. Remove the valve and spring. Pull the plunger out of the body to remove plunger, washer, and spring.
| NOTICE |
|---|
While disassembling fuel injection pumps, exercise considerable care to prevent damage to plunger surfaces. The body and plunger assemblies are matched and are not interchangeable with other bodies or plunger assemblies. |
5. Remove the cover (3). Remove the rack position indicator lever. Remove the timing pin assembly.
6. Remove the rack (4) from fuel injection pump housing.
7. Remove the lifter assemblies (5). Keep the lifter assemblies identified and together with their respective pumps.
| NOTICE |
|---|
Do not attempt to remove or replace the spacers in lifter assemblies (5). An improperly staked spacer can cause engine failure. |
8. Remove the fuel transfer pump drive shaft assembly (6), mounting bolts and lock.
9. Remove the fuel injection pump housing bottom cover. Pull the fuel injection pump camshaft (7) out of the housing.
10. Using tool setup (B), remove the camshaft bearings.
11. Remove the rack bearings using tool setup (C).
12. Remove the variable timing unit bearing from the fuel injection pump housing.
Assemble Fuel Injection Pump Housing
1. Using tool setup (A), install the variable timing unit bearing with the hole in bearing aligned with hole in fuel injection pump housing.
2. Install the three camshaft bearings using tool setup (C).
3. Install the two rack bearings using tool setup (B). The front rack bearing should be recessed .38 in. (9,65 mm) from the front face of housing. The rack rear bearing should be installed 6.372 in. (161,8 mm) from the variable timing unit end of fuel injection pump housing.
4. Lubricate the camshaft with clean engine oil and install it in housing. Install the fuel injection pump housing bottom cover. Install the fuel transfer pump drive shaft assembly, mounting bolts and lock.
5. Install the lifter assemblies (1) in their respective positions in housing. Lubricate the rack generously with clean fuel oil and install in housing.
NOTE: If new lifter assemblies and pumps are to be installed, it will be necessary to set the fuel pump timing dimension. See FUEL PUMP TIMING DIMENSION SETTING (OFF ENGINE) in TESTING AND ADJUSTING.
6. Install one of the timing pin retaining bolts, upside down, through one of the flange holes in timing pin assembly. Insert the pin assembly into the timing hole in housing. Move the rack back and forth slowly until the timing pin engages slot in rack. Depress the timing pin until head of inverted bolt touches housing.
| NOTICE |
|---|
Do not attempt to install fuel injection pumps if rack is not positioned as outlined above. |
7. Install rack position indicator lever and cover.
8. Assemble the fuel injection pumps as follows: Lubricate all parts generously with clean fuel oil. Install the spring, washer, and plunger in the body. Install the valve, spring, and bonnet in body. Using wrench (D), tighten bonnet to 145 ± 5 lb. ft. (20,05 ± 0,7 mkg).
9. Install the fuel injection pumps in their respective positions as follows: Rotate the camshaft until lifter assembly is down for the pump to be installed. Position the pump over the opening in housing. Sight down the pump and align the flat on gear with alignment pin in lifter assembly. Install the pump in housing. If the pump gear is properly aligned with alignment pin, the distance between pump body and fuel injection pump housing should be approximately 3/8 in. (10 mm) with the pump spring not compressed. Install the pump mounting bolts.
10. Install the fuel transfer pump-to-fuel injection pump housing adapter housing.
11. Remove the timing pin assembly from timing hole in fuel injection pump housing. Install the pin assembly in its storage position in housing.
concluding steps:
a) install variable timing unit
b) install governor
c) install fuel injection pump housing and governor as a unit