Diesel MFI Pump: Service and Repair

Fig. 1 Engine at TDC and injection:

Fig. 10 Alignment of injection pump marks:

1. Clamp and disconnect hoses at cold start device. Disconnect accelerator cable, kickdown cable, if equipped, and wire at stop valve.
2. Remove rear timing belt cover, clean and disconnect fuel line connections at injection pump. Plug open connections to prevent entry of dirt.
3. Remove vacuum pump and plunger. Clean and remove fuel delivery pipes and plug all connections to prevent entry of dirt.
4. Turn engine to No. 1 cylinder TDC and injection, Fig. 1. With flywheel mark at zero (0), pump sprocket notch must be aligned with mark on bracket and pump, Fig. 10.
5. Loosen injection pump bracket bolts and remove pump belt.
6. Remove camshaft rear sprocket using wrench 5199 or equivalent to hold gear, and wrench 5201 to loosen sprocket center nut. Do not allow camshaft to rotate, sprocket should rotate on camshaft.
7. Lock injection pump sprocket with stop 5193 or equivalent and using wrench 5201 or equivalent remove sprocket nut. Use puller 5204 or equivalent to remove sprocket.
8. Remove injection pump bracket bolts and remove pump with bracket. Remove Allen head bolts and separate pump from bracket.
9. Install new pump so mark on pump body aligns with mark on bracket. Install pump sprocket making sure that shaft key is correctly installed.
10. Refer to ``Injection Pump Setting'' procedure and set pump.
11. Fill pump with fuel if necessary and install rear timing belt cover.
12. Connect fuel supply and return lines. Do not switch connector screws. Screw for fuel return line has small hole and is marked OUT. Torque to 18 ft. lbs. (25 Nm).
13. Install fuel delivery pipes and torque cap nuts to 18 ft. lbs. (25 Nm). Install vacuum pump and plunger.
14. Connect cold start device hoses, stop valve wires, accelerator cable, and kickdown cable on automatic transmission models.

Fig. 11 Setting accelerator controls:

15. Set accelerator controls, Fig. 11, as follows:

Fig. 9 Connecting and disconnecting cold start device:

a. Disconnect cold start device, Fig. 9, and link rod at injection pump lever.
b. Adjust accelerator cable by turning cable sheath until cable is under tension but does not alter pulley position. Pulley should be at idle stop.
c. Depress accelerator pedal fully and check maximum accelerator position. Pulley should contact full throttle stop.
d. On automatic transmission models, kickdown cable should move about 2 inches between end positions when accelerator is floored. Cable should be under tension in idle position, and distance between kickdown cable clip and cable sheath should be 0.01-0.04 inch (0.25-1.00 mm).
e. Connect link rod to injection pump lever. Turn pulley to full throttle position and adjust link rod length so that pump lever contacts maximum speed adjusting screw.
f. Turn pulley to idle stop and move link rod ball joint in slot in injection pump lever until lever contacts idle adjusting screw.
g. Readjust link rod by repeating steps e and f until control is correctly adjusted. A maximum clearance of 0.012 inch (0.3 mm) is permissible at pulley stops.
h. Reconnect cold start device.