Injection Pump Timing

Use this timing procedure when installing a new injection pump. It is not necessary to use this timing procedure when removing and reinstalling the original injection pump. In that case, align the index marks on the injection pump and the gear case as they were before removing the injection pump.

  1. Before removing the old injection pump, note the alignment of the index marks on the injection pump and the gear case. The index mark on the injection pump is usually aligned with the index mark on the gear case. If not, make a mark on gear case in line with the index mark on the injection pump (see Marking Gear Case).

    Index Mark Location

    1. Index Marks

    Index Mark Alignment

    1. Index Mark on Injection Pump
    2. Index Mark on Gear Case

    Marking Gear Case

    1. Index Mark on Injection Pump
    2. Existing Index Mark on Gear Case
    3. Make New Mark on Gear Case If Needed

  2. Clean the area with brake cleaner or something similar. Place an injection angle sticker on the gear case so the center line on the sticker is aligned with the index mark on the injection pump. An injection angle sticker is provided with the new injection pump.

    Place Injection Angle Sticker on Gear Case

    1. Index Mark on Injection Pump
    2. Injection Angle Sticker

    Injection Angle Sticker

    1. –1.0 Degrees Mark
    2. Center Line (0 Degrees Mark)
    3. +1.0 Degrees Mark

  3. Remove the old injection pump. Use the injection pump gear tool P/N 204-1011 to remove the injection pump gear without removing the timing gear cover (see Injection Pump Removal).

    Note Remove the injection pump gear by removing the nut and lock washer that secure the injection pump gear assembly to the injection pump shaft. The injection pump gear assembly is made of three pieces; the flange, the gear, and the transfer pump cam. Do not loosen or remove the four bolts that fasten the gear to the flange because that changes the factory-set timing. The EPA certification is based on the factory-set timing. If the factory-set timing is changed, the EPA certification is void.

    Removing Injection Pump Gear

    1. Do Not Loosen or Remove These Four Bolts
    2. Remove Nut and Lock Washer

  4. Record the injection angle marked on the old injection pump (see the following photographs). The injection angle mark is located on the side of the pump facing the engine. The injection angle mark on the pump does not use a decimal point. Add a decimal point before the last digit of the injection angle mark to get the injection angle. The injection angle mark in the following photographs is 67. That equals an injection angle of 6.7 degrees.

    Examples
    Injection Angle Mark Injection Angle
    67 6.7 Degrees
    85 8.5 Degrees

    Injection Angle Mark Location

    1. Injection Angle Mark

    Injection Angle Mark

    1. Injection Angle Mark

    Note If you cannot read the injection angle mark, contact the Thermo King Service Department with the injection pump serial number or the engine serial number and they will provide the injection angle. The injection pump serial number is located on the bottom of the sticker on the injection pump.

    Injection Pump Serial Number Location

    1. Injection Pump Serial Number

  5. Record the injection angle marked on the side of the new injection pump.

  6. Calculate the injection angle difference by subtracting the injection angle of the old injection pump from the injection angle of the new injection pump.

    Examples
      Injection Angle of New Injection Pump (Degrees) 8.5 6.1
    – Injection Angle of Old Injection Pump (Degrees) – 6.7 – 6.7
    = Injection Angle Difference (Degrees) = +1.8 = –0.6

  7. Install the new injection pump on the gear case and position it so the index mark on the injection pump is aligned with the mark equal to the injection angle difference on the injection angle sticker (see the following examples). Tighten the injection pump mounting nuts when the index mark is aligned as necessary with the injection angle sticker.

    Examples of Injection Pump Index Mark Alignment with Injection Angle Sticker

    1. Injection Pump Index Mark at –0.6 Degrees
    2. Injection Pump Index Mark at +1.8 Degrees

  8. Install the injection pump gear, lock washer, and nut. Torque the nut to 78 to 88 N•m (58 to 65 ft-lb).

    9. Note If the timing gear cover was removed to remove the injection pump gear, make sure the timing marks on the timing gears are aligned as shown below. It helps to install the idler gear last when aligning the timing marks.

  9. Timing Mark Alignment

    1. Fuel Injection Pump Gear
    2. Idler Gear
    3. Camshaft Gear
    4. Crankshaft Gear

    10. Note The oil pump is located in the timing gear cover on TK486V25 / TK486V25L / TK486V25L1 / TK486V25X / TK486V25X1 / TK486VHA engines. The inner rotor of the oil pump fits around the crankshaft gear. Make sure that the flat sides of the inner rotor are aligned with the flat sides on the crankshaft gear when installing the timing gear cover.

  10. Align Flat Sides of Crankshaft Gear with Flat Sides of Inner Rotor in Timing Gear Cover

    1. Crankshaft Gear
    2. Oil Pump Cover
    3. Outer Rotor
    4. Inner Rotor
    5. Timing Gear Cover
    6. Flat Sides on Inner Rotor
    7. Flat Side on Crankshaft Gear

Parent topic: Engine Fuel System