Diesel injection pump, removing and installing: Installing

• Insert injection pump into bracket and then tighten mounting bolt on rear support with conical nut first.
• Align so injection pump is centered in elongated holes in bracket, and hand-tighten in this position.

• Install injection pump sprocket and lock into position using 2064 lock pin. Make sure spring washer is correctly seated.
• Tighten mounting nut.

  Tightening torque: 55 Nm (41 ft lb)

• Loosen camshaft sprocket mounting bolt 1/2 -turn.
• Place drift through hole in rear belt guard, tap carefully with hammer to release sprocket from tapered end of camshaft, and remove camshaft sprocket.
• Check to make sure that TDC mark on flywheel and reference mark on transmission housing are aligned.
• Place belt on injection pump sprocket and tensioner roller.
• Install camshaft sprocket on toothed belt and secure sprocket so camshaft can still turn.
• Install idler roller.
  Fig 1: Installing Injection Pump Sprocket And Locking Into Position Using 2064 Lock Pin

  

• Remove locking pin from injection pump sprocket.
• Adjust toothed belt tension using pin wrench on eccentric (e.g. Matra V159); turn clockwise until notch and raised mark (arrows) are aligned.
Fig 2: Turning Toothed Belt Tensioner Clockwise To Align Notch And Raised Mark

• Tighten mounting nut.

  Tightening torque: 20 Nm (15 ft lb)

• Check TDC mark on flywheel again.
• Tighten camshaft sprocket mounting bolt.

  Tightening torque: 45 Nm (33 ft lb)

• Remove 2065A setting bar from camshaft.
• Fill injection pump with clean Diesel fuel through return line union.

  New pump fill quantity: 180 ml minimum

• Re-connect injector lines, fuel lines and wiring.
• Install belt guard, cylinder head cover and air cleaner.
• Dynamically check start of injection and adjust if necessary.

See START OF INJECTION, DYNAMICALLY CHECKING AND ADJUSTING 

• Check and erase DTC memory, see ERASE DTC MEMORY (SCAN TOOL FUNCTION 05) .
• Re-create readiness code, see READINESS CODE, SETTING (UP TO M.Y. 1997) .