3204 engine. Has exact same inject pump as in pic(swiped from net) Had lift pump leaking issues last year, changed it out only to find out still getting diesel in oil. Going to remove injector pump to have it leak tested/rebuilt...whichever is the case to stop the diesel getting into crankcase. Ive beat around the net for how tos and steps on how to remove this and preserve timing. Pin the flywheel, while the timing pin is lined up in the injector pump slot too (is this foolproof correct??) Would this insure that it cant be 180 degrees off...when reinstalling later?? Or am i missing something on insuring at TDC on 1 when pinned? PLEASE ADVISE. One more item, pulling the front injector pump drive gear. I know to loosen the pump but leave bolts in place to then tackle this gear. Currently i have no specific puller to bust this loose. How hard is it to accomplish this with reg. tools and not purpose built puller for this job. PLEASE ADVISE. Im not a mech. and dont claim to be either...but im willing to attempt this with almost zero diesel wrenching experience THANKS IN ADVANCE
PEVO, Good question. Yes, you could be pinned 180 degrees off. Best way to tell is to remove the valve cover and watch the valves on cylinder one while you turn the engine. The intake valve should be closing as you approach TDC. To unstick the pump drive from the gear, I will install the bolt with a few threads engaged and give it a tappy-happy with a three-pound plastic dead blow. Not a bang-bang, just a tappy-tappy.
Even with the recommendation puller installed, the tapered shaft engagement is a little stubborn. A tappy-tappy does the trick.
If the gear has threaded holes for a puller. I have taken the t-bar from a slide hammer attachment and a bolt to press the gear off the pump shaft.
I may not be understanding correct, or just wrong. The injection pump goes around once for every two revolutions of the crankshaft, so the injection timing being lined up and the engine being pinned should guarantee it's TDC. Easy enough to check, turn the engine around one more time till the pin fits again, and see if the injection pump is lined up.
Delmer, You are correct. Good point. If both pins drop in, it should be TDC#1.
I always pin the pump first that way you will be one #1 TDC. I unbolt the pump have some one pry it back with a bar loosen the bolt and hit it with a 5 lb hammer you will have to take off the fan guard in order to get a good swing
Have you checked to make sure you injection lines or injectors are not leaking under valve cover
yes that was the first thing i checked. Ran for 30-45 sec with valve cover off visually seen no leaks. Thats when i moved to transfer/lift pump. Had it checked out and found it was leaking so i replaced it. Changed oil and used it on an off for a few hours...noticed oil level was again rising (just not quite as fast). Now injector pump is suspect.
well after hours of cussing, banging and scraping knuckles searching for the right sockets, rachets, extensions, plus box end angled, straight wrenches....I finally got this damn Injector pump off. That third hidden nut below/semi behind this pump that was recessed into a little niche...WAS a BITCH to get AT and loosen. It deified all efforts to get a box end on it. (it was inbetween lobes) The open end caught it BUT you didnt have enuff travel to break it loose. I FINALLY forced a shallow 9/16 1/4drive socket onto it and was able to put a 1/4 drive ratchet (3/8 ratchet would'nt fit...too big) onto it and one click at a time finally loosen this nightmare of a nut and get the pump off. The instructions i had said NOTHING about the large washer on the end of the pump gear that attaches to the pump tapered shaft under the end bolt. Whew...I could really screwed the pooch if id let it fall into the timing gear front housing. I got that puckered up feeling just pulling this bolt out knowing full well one wrong move and DAMN take apart the front of the engine to fish damn washer out! Anyways its at the diesel injection service place now. Thanks all
This may not work in your particular situation. But every time I was in a position that a washer or bolt could drop in the worst places, I would stuff rags in every little crack and crevice to close the opening.
Get your self a 9/16 3/8 drive universal socket it will go right on there with a long extension