Injection Pump Removal

The injection pump drive gear will not fit through the gear housing when removing the pump, the gear must be separated from the pump. Using tool P/N 204-1011, it will not be necessary to remove the belts, crankshaft pulley, crankshaft seal or front plate. See Injection Pump Gear Tool.

  1. 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 single index mark on the gear case. If not, mark it so the injection pump can be returned to the same position when it is reinstalled.

    Index Mark Location

    1. Index Marks

    Index Mark Alignment

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

  2. Remove the starter for clearance, remove throttle linkage, fuel lines, harness and mounting hardware from injection pump.

  3. Remove the cover plate from the gear case. Remove the nut and lock washer which secure the gear to the injection pump shaft. Use a shop rag to prevent the lock washer or nut from falling into the gear case.

    Note 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 timing.

  4. Use the hardware from the cover plate to attach the tool plate (with the marked side pointing up and out) to the gear case.

  5. Align the threaded holes in the injection pump gear with the two holes in the tool plate by rotating the engine crankshaft. Attach the gear to the tool plate with the screws provided with the tool plate.

  6. Thread the long screw supplied with the tool plate into the small end of the adapter, also supplied with the tool plate. Insert the adapter into the tool plate and rotate to provide a solid position to force the injection pump shaft from the gear. Caution should be made to align the screw over the center of the injection pump shaft.

  7. Remove the screw and adapter leaving the tool plate in place. This holds the gear in proper tooth alignment until the injection pump is re-installed.

Injection Pump Gear Tool

1. Injection Pump 5. Adapter (Tool)
2. Gear Case 6. Tool Long Screw (Tool)
3. Cover Plate 7. Tool Short Screw (Tool)
4. Cover Plate Bolt 8. Tool Plate (Tool)
Parent topic: Engine Fuel System