Fuel Injection System - 6.2l Diesel Chevrolet Forward Control P30

COMPONENT TESTING

Note. Specific component testing information not available. Refer to any tests performed during REMOVAL & INSTALLATION or OVERHAUL procedures

DESCRIPTION

General Motors 6.2L engine uses a mechanical high pressure rotary pump, gear driven by camshaft at camshaft speed. It injects a precisely metered amount of fuel to each cylinder at the proper time.

A mechanical fuel pump, mounted on right of engine, pulls fuel from fuel tank through a primary filter. Fuel is pumped through a secondary filter mounted on firewall (pickups) or rear of air cleaner (vans) to the injection pump. High pressure fuel lines carry fuel from pump to 1 injection nozzle in each cylinder. All fuel lines are the same length to ensure that there is no variance in timing. Engine RPM is controlled by a rotary fuel metering valve. As accelerator pedal is pushed down, throttle linkage opens metering valve to allow increased fuel delivery.

Diesel Injection System Fuel Circuit. Scheme 14

Note. Secondary fuel filter is mounted on firewall (pickups) or rear of air cleaner (vans).

AIR INDUCTION SYSTEM

Intake manifold is always open to atmospheric pressure. Intake manifold has a single inlet for drawing air through an air filter assembly mounted above. Manifold consists of 8 branches, one leading to each cylinder.

DIESEL INJECTION PUMP

The high pressure diesel injection pump is mounted at top of engine below intake manifold. The pump is gear driven by camshaft at camshaft speed. Pump precisely governs time and amount of fuel injection.

A built-in fuel pressure regulator and transfer pump picks up fuel at pump inlet, pushing it through a passage to the pump head. The pump head distributes fuel at transfer pump pressure (8-12 psi) to metering valve, governor and automatic advance mechanisms. Fuel then passes to rotary fuel metering valve and into a charging passage. As pump shaft rotates, fuel is directed at high pressure through each delivery pipe to an injector. Pump is not serviceable and must be exchanged in the event of a malfunction.

Diesel Injection Pump. Scheme 15

Note. Pump is serviceable as a complete unit, only.

FUEL INJECTION LINES

Eight high pressure fuel injection lines are routed from injection pump to an injector in each cylinder. The lines are of equal length but are bent differently to maintain equal length, prevent any difference in timing from cylinder-to-cylinder and aid installation. Lines are not interchangeable and are pre-bent by the manufacturer.

GLOW PLUGS

Glow plugs are threaded into each cylinder combustion chamber. Glow plugs are small heaters that assist in cold starting. The glow plug controller/relay (mounted on top-rear of engine) cycles 12 volts to these 6 volt heaters, which causes them to heat rapidly. After the engine starts, glow plugs continue to cycle on and off for about 25 seconds, depending on coolant temperature.

Note. Any attempt to by-pass relay with jumper wire may result in glow plug failure.

INJECTION NOZZLES

Each engine cylinder combustion chamber is equipped with 1 injection nozzle. The injection nozzle has a single fuel inlet fitting and 2 fuel return fittings (1 on each side of fuel inlet fitting). The nozzle is threaded into the cylinder head. Injection nozzles are spring loaded and calibrated to open at a specified fuel line pressure. The combustion chamber end of the nozzle has a replaceable compression seal and carbon stop seal.

Injection Nozzle Installation. Scheme 16

Note. Last nozzle on cylinder bank has 1 fuel return fitting plugged.

VACUUM PUMP

Vacuum to operate accessory systems on diesel vehicles is provided by a vacuum pump which is located at the rear of the block and driven by the cam. The engine should never be operated without the vacuum pump in place as it is also the oil pump drive.

HOUSING PRESSURE COLD ADVANCE (HPCA)

The HPCA circuit is used to improve cold starting and aid emission control. The circuit is controlled by a temperature switch located on rear of right-hand cylinder head. The circuit advances injection timing about 4° when the engine is cold.

When engine temperature is below 95°F (35°C), the circuit decreases housing pressure from 10 psi to zero. At the same time, the fast idle solenoid is activated. When the temperature switch opens, the HPCA circuit is de-energized and housing pressure rises, retarding pump timing. The temperature switch will close again when engine temperature falls below 85°F (30°C).

DIESEL FUEL HEATER

This option is used to heat the fuel during low temperature operation, below 20°F (B 5°C). This prevents wax crystals from building up and blocking the fuel filters. The heater is located along the right side of the intake manifold and uses a resistance wire spiralled around the fuel line.

ADJUSTMENT

Note. For on-vehicle adjustments not given here, see TUNE-UP SERVICE PROCEDURES article.

Scheme 17

1. The vacuum regulator valve provides vacuum signals to control transmission shift points. Vacuum setting of valve should be checked periodically, using the following procedure. Engine MUST NOT be running during this procedure.
2. Attach vacuum regulator valve snugly to fuel injection pump. Switch body must be free to rotate on pump.
3. Attach vacuum source of 20 in. Hg. to bottom vacuum nipple. Insert vacuum regulator valve Gauge Block (J-33043-2) between gauge boss on injection pump and wide open stop screw on throttle lever (switch on position). see scheme 5: Vacuum Regulator Gauge Block
4. Rotate and hold throttle shaft against gauge. Slowly rotate vacuum regulator valve body clockwise (facing valve) until vacuum gauge reads 8 F.6 in. Hg. Hold valve body at this position and tighten mounting screws.
5. Check by releasing throttle shaft allowing it to return to idle stop position. Then rotate throttle shaft back against gauge block to determine if vacuum gauge reads within 8 F.6 in. Hg. If vacuum is outside limits, reset valve.

Engine Wiring System Diagram. Scheme 18

Glow Plug System Diagnosis (C/K, R/V, G, P). Scheme 19

Glow plug system charts should be used only after ensuring that glow plug system is properly installed. Check that all connectors are correctly installed and that all connections are clean and tight.

The PRELIMINARY DIAGNOSIS chart provides a quick procedure for determining if a problem exists in the glow plug system itself, or elsewhere in the electrical system. (Scheme 20) This test should always be completed before proceeding with the ELECTRICAL SYSTEM DIAGNOSIS chart. (Scheme 21)

Preliminary Diagnosis. Scheme 20

Electrical System Diagnosis. Scheme 21

GLOW PLUG RESISTANCE TEST

1. Start engine, turn on heater and allow engine to warm up. Remove all electrical feed wires at glow plugs.
2. Use a magnetic pickup tachometer to adjust engine speed. Turn idle speed screw on side of injection pump until engine idle is roughest. About 860 RPM is desirable, but do not exceed 900 RPM.
3. Allow engine to run for 1 minute at roughest idle. Thermostat must be open and upper radiator hose hot.
4. Attach jumper wire between voltmeter ground lead and engine lift point on left side of intake manifold. DO NOT use any other point for ground connection. Ground wire must remain in position until all tests have been completed.
5. Check resistance by touching positive lead of voltmeter to glow plug terminal (with engine running). Record value obtained in firing order sequence (1-8-7-2-6-5-4-3).
6. If ohm reading on any cylinder is about 1.2-1.3 ohms, make a compression check on that cylinder before continuing diagnosis. Most cylinders should measure 1.8-3.4 ohms. If more than .3 ohms difference exists between 2 consecutive cylinders in firing order, remove injectors and check opening pressure.
7. Improve rough idle by switching nozzles. Install nozzles with higher opening pressure to decrease ohm reading, and lower opening pressure to raise ohm reading.
8. Repeat procedure to confirm idle improvement. Be sure to check glow plug resistance at the same idle speed both times. If no improvement is observed, injection line replacement or injection pump calibration may be necessary.

GLOW PLUG CONTROLLER

A faulty controller/relay assembly may result in excessive white smoke in exhaust and/or poor idle immediately after starting. The following procedure checks for proper operation of controller circuit.

Note. Engine coolant temperature must be below 80°F (27°C) before beginning test.

1. Turn ignition to "RUN" and allow glow plugs to cycle. Wait 2 minutes, then turn ignition to "CRANK" for 1 second and back to "RUN". Glow plugs should cycle on at least once. If glow plugs do not cycle as described, proceed to step 2.
2. Disconnect controller connector. Connect 12-volt test light between harness connector terminal "B" (Purple wire) and ground. With ignition in "RUN" position, test light should be off. With ignition in "CRANK" position, light should be on.
3. If test light does not operate as described, repair short or open in engine harness Purple wire. If light operates properly but glow plugs did not cycle in step 1, replace controller.

INJECTION PUMP HOUSING FUEL PRESSURE

1. Remove injection pump and drain all fuel. Connect an air supply line to fuel inlet fitting. Be sure air supply is clean and dry.
2. Seal the return line fitting. Completely immerse pump assembly in a container of clean test oil.
3. Apply 20 psi (1.4 kg/cm 2 ) to pump. Leave pump immersed for 10 minutes to allow any trapped air to escape. Watch for leaks after 10 minutes.
4. If no leaks are noticed after 10 minutes, reduce air pressure to 2 psi (.14 kg/cm 2 ) for 30 seconds. If there are still no leaks, increase pressure to 20 psi (1.4 kg/cm 2 ) again.
5. If no leaks are observed, pump is serviceable. If leaks are observed, pump must be exchanged for replacement unit.

INJECTION NOZZLE

Test Preparation

1. Remove injection nozzle from engine. Clean carbon from tip area of nozzle with soft brass wire brush. DO NOT use steel brush or motorized brush to clean nozzle tip. Damage to nozzle tip may result.
2. Connect nozzle assembly to injection nozzle tester. Close tester shut off valve to pressure gauge. Fill tester with test fluid. Fill and flush nozzle assembly with test oil by operating tester lever briskly and repeatedly. This purges air from nozzle and coats all parts with test fluid.

Opening Pressure Test

1. Open tester shut off valve to pressure gauge 1/4 turn. Slowly depress tester lever and observe pressure gauge. Note pressure at which needle stops, indicating pressure increase (nozzle does not chatter) or at which pressure drops substantially (nozzle chatters).
2. Maximum pressure is opening pressure. Lowest acceptable pressure is 1500 psi (105 kg/cm 2 ). Replace any nozzle which does not meet lowest acceptable pressure. Release tester pressure.

Leakage Test

1. Open tester shut off valve to pressure gauge an additional 1/2 to 1 1/2 turns. Blow dry nozzle tip. Connect a short piece of clear plastic tubing to each fuel return fitting on nozzle.
2. Slowly depress tester lever until pressure gauge reads 1400 psi (98 kg/cm 2 ). Maintain pressure for 10 seconds and observe nozzle tip.
3. Replace nozzle assembly if drop of test fluid drops from tip within 10 seconds. A drop may form but not drop off within the specified time period. (Scheme 22) Release tester pressure.

Nozzle Leakage Test. Scheme 22

Chatter Test

Note. The sound (chatter) for new and used nozzles may vary. With some used nozzles, chatter is difficult to detect during slow actuation of hand test stand lever. Some nozzles may chatter louder than others. As long as there is chatter, the nozzle is acceptable.

1. Close tester shut off lever at pressure gauge. Slowly depress lever of manual test stand noting whether chatter noises can be heard.
2. If no chatter is heard, increase speed of lever movement until it reaches a point where the nozzle chatters. At fast lever movement, the nozzle may emit a "hissing" or "squealing" sound rather than the normal chatter. This is acceptable.
3. These sounds indicate that the nozzle needle moves freely and that the nozzle seat, guide and pintle have no mechanical defects. Replace any nozzle assembly which does not chatter.

Spray Pattern Test

The injection nozzles used with this system have several features which make pattern testing difficult, i.e. longer nozzle overlap and greater pintle to body and needle to body clearances than other nozzle types, and an internal wave washer between the nozzle nut and nozzle. Typical injector testers cannot deliver fuel with sufficient velocity to obtain proper spray patterns. Therefore, this type nozzle should not be rejected due to spray pattern.

REMOVAL & INSTALLATION

Note. Manufacturer does not recommend disassembly of pump. However, the following seals can be replaced with the injection pump installed on the engine. For problems not covered in this article, pump must be removed and taken to an authorized repair station.

Pump Cover Seal & Guide Stud Seal

1. Disconnect ground cables from both batteries. Remove air cleaner and air cleaner intake. Install Screens (J-29664) in cylinder heads to prevent entrance of dirt. Disconnect fuel return line and wiring from injection pump.
2. Remove throttle cable and return springs. Remove top fast idle solenoid attaching bolt. Loosen lower bolt and move solenoid aside. Clean injection pump cover and area around throttle rod and guide stud. Place rags in engine valley to catch fuel. Remove injection pump cover and remove screws from cover. NOTE: After removing injection pump cover, use extreme care to prevent dirt or other foreign matter from entering pump.
3. Note position of metering valve spring over top of guide stud. This position must be exactly duplicated during reassembly. Remove guide stud and washer. (Scheme 23)
4. Install guide stud with new washer. Ensure that upper extension of metering valve spring rides on top of guide stud. Carefully tighten guide stud.
5. Hold throttle in idle position. Install new pump cover seal. Make sure cover screws are removed from cover. Position cover about 1/4" forward (toward shaft end) and about 1/8" above pump. (Scheme 24)
6. Using care not to cut seal, move cover rearward and downward into position. Install cover screws with flat washer against cover. Use care not to drop lock washers or flat washers into pump. Tighten screws.
7. Reconnect negative battery cables to both batteries. Turn ignition switch to "RUN" position. Momentarily touch Pink solenoid wire to solenoid. A clicking noise should be heard as wire is connected and disconnected at solenoid. If clicking noise is heard, go to step 10. If not, go to step 8.
8. If clicking noise is not heard, linkage may be jammed in wide open throttle position. Engine MUST NOT be started. Remove cover.
9. Ground solenoid lead (opposite "hot" lead) and connect Pink wire. With ignition switch in "RUN" position, solenoid in cover should move the linkage. If not, replace solenoid. Repeat steps 5 through 7. Minimum voltage across solenoid terminals must be 12 volts.
10. If clicking noise is heard, connect pump solenoid and HPCA wires. Install fuel return line, throttle cable and return springs. Reposition fast idle solenoid.
11. Start engine and check for leaks. Idle roughness may occur due to air in fuel system. Allow plenty of time for air to be purged from system. Engine may have to be stopped to allow air in injection pump to rise to top of pump for purging.
12. Remove cylinder head screens. Install air cleaner intake and air cleaner.

Guide Stud Seal Replacement. Scheme 23

Injection Pump Cover Installation. Scheme 24

Throttle Shaft Seal

1. Disconnect ground cables from both batteries. Remove air cleaner and air cleaner intake. Install screens in cylinder heads to prevent entrance of dirt. Disconnect fuel return line and wiring from injection pump.
2. Mark position of throttle position switch (TPS) or vacuum regulator valve for reassembly. Remove throttle rod and return springs. Loosen fast idle solenoid and move aside. Remove throttle cable bracket.
3. Install Advance Cam Adjuster (J-29601) over throttle shaft with slots of adjuster engaging pin. Place spring clip over throttle shaft advance cam and tighten wing nut. Without loosening wing nut, pull adjuster off throttle shaft to provide alignment for reassembly. (Scheme 25)
4. Drive pin from throttle shaft. Remove throttle shaft advance cam and fiber washer. Remove any burrs from throttle shaft after removing cam. Clean injection pump cover, upper portion of pump, throttle shaft and guide stud area. Place rags in engine valley to catch fuel. Remove injection pump cover and remove screws from cover. NOTE: DO NOT allow any dirt or foreign objects to drop into injection pump after cover is removed. Pump damage may result.
5. Note position of metering valve spring over top of guide stud for reassembly reference. Note position of guide stud and washer. Remove guide stud and washer. (Scheme 26)
6. Rotate min/max governor assembly up to provide clearance and remove from throttle shaft. If idle governor spring becomes disengaged from throttle block, reinstall with tightly wound coils toward throttle block.
7. Remove throttle shaft and inspect. If damaged or worn, replace. Inspect throttle shaft bushings for damage, wear or leaks. If bushing replacement is required, pump must be sent to authorized repair station.
8. Remove throttle shaft seals. DO NOT cut seals for removal. A nick on shaft will cause leakage. Lightly coat new seals with grease. Install seals on shaft without cutting seals on sharp edges of shaft.
9. Carefully slide shaft into pump until min/max governor assembly will slip onto throttle shaft. Rotate governor downward and hold in position. Slide shaft and governor into place.
10. Install new fiber washer, throttle shaft advance cam ( DO NOT tighten cam screw) and throttle shaft drive pin. Align advance cam so advance cam adjuster can be reinstalled over throttle shaft. Install pin in slots and spring clip over advance cam.
11. Insert.005" (.13 mm) feeler gauge between white washer on throttle shaft and pump housing. Squeeze throttle shaft and tighten cam screw. Remove adjuster.
12. Install guide stud with new washer. Ensure that upper extension of metering valve spring rides on top of guide stud. Tighten guide stud.
13. Hold throttle in idle position. Install new pump cover seal. Make sure cover screws are removed from cover. Position cover about 1/4" forward (toward shaft end) and about 1/8" above pump. (Scheme 24)
14. Using care not to cut seal, move cover rearward and downward into position. Install cover screws with flat washer against cover. Use care not to drop lock washers or flat washers into pump. Tighten screws. Install vacuum regulator or TPS.
15. Reconnect negative battery cables to both batteries. Turn ignition switch to "RUN" position. Momentarily touch Pink solenoid wire to solenoid. A clicking noise should be heard as wire is connected and disconnected at solenoid. If clicking noise is heard, go to step 18. If not, go to step 16.
16. If clicking noise is not heard, linkage may be jammed in wide open throttle position. Engine MUST NOT be started. Remove cover.
17. Ground solenoid lead (opposite "hot" lead) and connect Pink wire. With ignition switch in "RUN" position, solenoid in cover should move linkage. If not, replace solenoid and repeat step 15. Minimum voltage across solenoid terminals must be 12 volts.
18. If clicking noise is heard, connect pump solenoid and HPCA wires. Install fuel return line, throttle cable, throttle cable bracket and return springs. Reposition fast idle solenoid.
19. Start engine and check for leaks. Idle roughness may occur due to air in fuel system. Allow plenty of time for air to be purged from system. Engine may have to be stopped to allow air in injection pump to rise to top of pump for purging.
20. Remove cylinder head screens. Install air cleaner intake and air cleaner.

Note. The following seals must be replaced with the injection pump removed from the engine. For problems not covered in this article, pump must be removed and taken to an authorized repair station.

Advance Cam Adjuster Installed On Injection Pump. Scheme 25

Advance Pin Hole Plug Seal

1. Tap advance pin hole plug lightly with a hammer to loosen. Remove plug. Remove and discard seal. (Scheme 26)
2. Lubricate and install new seal. Install and tighten plug.

Exploded View of Automatic Advance Assembly. Scheme 26

Automatic Advance Seals

1. Remove advance pin hole plug as previously described. Remove spring side advance piston hole plug. Remove plug, piston, spring and washer.
2. Remove power side advance piston hole plug. Remove plug, piston and washer. Disassemble plugs and pistons. Discard seals.
3. Lubricate and install new seals. Reverse removal procedure and tighten plugs. (Scheme 26)

Hydraulic Head Seal

1. Remove throttle shaft and seals as previously described. Remove metering valve. Remove housing vent screw assembly. Remove advance pin hole plug and advance pin.
2. Install pump in holding fixture so that rear of pump is tilted downward. Remove hydraulic head locating screw. Remove 2 hydraulic head locking screws and discard seals.
3. Using a twisting motion, remove hydraulic head from pump assembly. Remove and discard "O" ring seal.
4. Lubricate and install new seal. Install hydraulic head into pump assembly. Lubricate and install 2 locking screw seals. Install locating screw. Install and tighten locking screws.
5. Install advance pin, advance pin seal and advance pin hole plug. Position pump so cover opening is up, and install metering valve. Install throttle shaft, seals and pump cover.

Injection Pump Fuel Line Routing. Scheme 27

Drive Shaft Seal

1. Mount pump in Holding Fixture (J-29692-B) and tilt pump slightly towards you. Remove fast idle solenoid bracket.
2. Remove drive shaft from pump with a rotating motion while pulling on shaft (shaft is retained by "O" ring clip). Remove and discard drive shaft seals.
3. Install new seals with Seal Installer (J-29745-A). Lubricate installer with light grease and install 1 Black seal. Lubricate installer again and install Red seal. Lubricate installer once more and install remaining Black seal.
4. Install a new "O" ring retaining clip on drive shaft. Install drive shaft, ensuring that drill points on shaft end and rotor are matched. Install fast idle solenoid bracket.

Removal (Pickup)

1. Disconnect negative battery cables. Disconnect air cleaner bracket from valve cover. Remove crankcase vent bracket and move aside.
2. Loosen vacuum pump hold-down clamp. Rotate pump to gain access to intake manifold bolt. Remove intake manifold. Install screens in cylinder heads.
3. Remove injection line clips at loom brackets. Remove injection lines at injection nozzles. Remove lines at pump. Tag lines for reassembly reference. Cap open lines.

Installation

1. Remove caps from lines and install injection lines. Ensure lines are properly positioned. (Scheme 27)
2. Reverse removal procedures to complete installation. After installation, start engine and check for leaks.

Removal (Van)

1. Disconnect negative battery cables. Remove engine cover and air cleaner. Disconnect necessary wires and hoses. Remove EGR/EPR switches.
2. Remove crankcase depression regulator valve hoses from intake manifold. Remove rear A/C compressor bracket (if equipped).
3. Remove fuel filter to intake manifold bracket. Remove vacuum pump. Place a rag or cover over hole to prevent foreign material from entering engine. Remove intake manifold bolts and fuel line clips. Remove intake manifold.
4. Install screens in cylinder heads. Remove injection line clips at loom brackets. Raise vehicle (for left bank).
5. Remove injection lines at injection nozzles. Lower vehicle. Remove lines at pump. Tag lines for reassembly reference. Cap open lines.

1. Remove caps from lines and loosely install injection lines. Ensure lines are properly positioned.
2. Reverse removal procedures to complete installation. After installation, start engine and check for leaks.

1. Disconnect negative battery cables. Remove fan, shroud, air cleaner and intake manifold. Install screens in cylinder heads. Remove fuel injection lines as previously described.
2. Disconnect throttle cable, return springs and detent cable (if equipped). Disconnect wires, fuel return line, fuel supply line and fuel injection lines at pump. Cap all fuel lines.
3. Remove A/C hose retainer bracket, if equipped. Remove oil filler tube and PCV vent hose assembly. Remove grommet. Scribe or paint an alignment mark on front cover and injection pump.
4. Rotate engine to remove injection pump retaining bolts that are accessible through oil filler neck hole. Remove injection pump-to-front cover nuts. Remove injection pump and gasket.

1. Install new injection pump gasket. Position cylinder No. 1 at TDC by lining up crankshaft pulley mark with indicator. Align locating pin on injection pump hub with slot in injection pump driven gear. At the same time, align injection pump timing marks. (Scheme 28)
2. Attach injection pump to front cover. Alignment marks made during removal must be aligned. Tighten nuts. Attach pump to drive gear and tighten bolts.
3. To complete installation, reverse removal procedure. Check timing and perform on-vehicle adjustments, if required.

Injection Pump Timing Mark Locations. Scheme 28

1. Disconnect negative battery cables. Remove engine cover and air cleaner. Disconnect necessary wires and hoses. Remove EGR/EPR switches.
2. Remove crankcase depression regulator valve hoses from intake manifold. Remove rear A/C compressor bracket (if equipped).
3. Remove fuel filter to intake manifold bracket. Remove vacuum pump. Place a rag or cover over hole to prevent foreign material from entering engine. Remove intake manifold bolts and fuel line clips. Remove intake manifold.
4. Rotate snorkel of air cleaner inlet hose up. Remove hood latch, disconnect cable and move aside.
5. Remove windshield washer bottle, fan shroud bolts and upper shroud. Disconnect rubber hose from oil fill tube. Disconnect oil fill tube attaching nuts and remove oil fill tube.
6. Remove oil fill tube grommet. Rotate engine as necessary and remove drive gear to pump bolts. Remove fuel filter and bracket including line to injection pump.
7. Disconnect wire looms from injection lines and injection lines at brackets. Disconnect oil pan dipstick tube at left cylinder head.
8. Disconnect electrical connections at injection pump. If equipped with automatic transmission, disconnect TV cable. Disconnect accelerator cable.
9. Disconnect injection lines at nozzles 2, 4, 5, 6, 7 and 8. Raise vehicle and disconnect remaining lines. Cover nozzles 1, 3, 5 and 7.
10. Lower vehicle. Cover nozzles 2, 4, 6 and 8. Disconnect injection lines at pump and remove lines. Tag lines for reassembly reference. Cap all fuel lines.
11. Disconnect fuel return line. Scribe or paint a mark on front cover and pump flange. Remove pump to front cover attaching nuts. Remove injection pump. Cap all open discharge fittings.

1. Install new injection pump gasket. Align locating pin on injection pump hub with slot in injection pump driven gear. At the same time, align injection pump timing marks. (Scheme 28)
2. Attach injection pump to front cover. Alignment marks made during removal must be aligned. Tighten nuts. Attach pump to drive gear and tighten bolts.
3. To complete installation, reverse removal procedure. Check timing and perform on-vehicle adjustments, if required.

Removal

1. Disconnect negative battery cables. Disconnect fuel line clip. Remove fuel return line from nozzle without bending line. Remove fuel injection line.
2. Using Injector Remover/Installer (J-29873), remove injection nozzle. Always remove injector by placing remover on 30 mm hex flats of injector body to prevent damage to injector body. Cap injector and lines.

1. Remove caps from injector and fuel lines. Install injector nozzle with installer. Connect fuel line.
2. Install fuel return hose and fuel line clip. Connect battery cables. Start engine and check for leaks.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS