Inspection and Repair. - TM-5-2410-233-340148

f. Reassembly (fig. 5-19).

(2) Remove the fuel injection pump retailing

bushing (3) from the housing.

NOTE

Immerse all parts in clean diesel fuel before

(3) Using an extractor, remove the fuel in-

reassembling.

jection pump from the housing.

(1) Install the bearing (25) so that the hole in

NOTE

the bearing aligns with the oil passage in the

Components of the fuel injection pumps cannot be

interchanged. Tag parts for assembly with the same

housing. Install the bearing (24). Ensure that the

parts and installation in the same bore in the fuel

bearings are flush with the face of the housing.

pump housing.

(2) Install the camshaft (23) in the housing.

(3) Install the spacer (22), ring gear (21),

(4) Remove the retaining ring (4) and

spring (20), spring retainer (19), lock (18) and bolt

separate the bonnet (5) from the barrel (6).

(17).

(5) Remove the check valve (7) and spring (8)

(4) Install the valve lifter (16) and sparer

from the bonnet.

(15).

(6) Remove the plunger (9), keeper (10) and

spring (11) from the barrel (6).

(5) Install the bearing (14) so that the hole in

the hearing aligns with the marks made on the

(7) Remove the fuel rack (12) from the

housing before removal. Install the bearing (13)

housing.

(6) Install the fuel rack (12).

(8) Remove the bearing (13) from the

housing.

(7) Install the spring (11), keeper (10) and

plunger (9) in the barrel (6).

(9) Scribe two marks on the housing above the

groove on the bearing (14) and in line with the

(8) Install the spring (8) and check valve (7)

in the bonnet (5).

lubrication passage. Remove the bearing.

(9) Secure the bonnet (5) to the barrel (6)

(10) Remove the spacer (15) and the valve

lifter (16).

using retaining ring (4). Install the barrel and

bonnet assembly in the fuel pump housing. Align

(11) Remove the bolt (17), lock (18), spring

the notches in the bonnet and barrel with the mark

retainer (19) and spring (20).

180 from the gear center tooth. Align the notches

(12) Remove the ring gear (21) and spacer

with the guide pins in the housing bore. Align the

(22).

pump gear center tooth with the fuel rack center

(13) Remove the camshaft (23) from the

notch.

housing.

(14) Remove the bearing (24 and 25). Scrape

(10) Press down on the barrel and bonnet

assembly and install the retaining bushing (3) flush

the gaskets (26 and 27) from the housing (28).

with the top of the housing. If the bushing cannot

d. Cleaning. C l e a n all components except

be properly installed, remove the barrel and

bearings with Fed. Spec. P-D-680 cleaning solvent

bonnet, realign and reinstall. Tighten the bushing

and dry with compressed air. Clean bearings as

to a torque of 140 to 160 foot-pounds.

instructed in paragraph 2-6.

(11) Install the felt washer (2) and the cap

e. Inspection and Repair.

(1).

(1) Inspect all components for cracks, chips,

g. Installation. Install the fuel injection pump in

nicks, grooves, scores, pitting and wear. Repair or

the reverse order of removal. Tighten bolts and

replace parts as required.

fittings securely. Check and adjust timing (subpara

(2) Inspect the sliding surfaces of pump

h, i, or j) and fuel rack setting (subpara k ).

plungers for grooves and scratches. Ensure that

h. Checking Fuel Injection Pump Timing (On

edges are not rounded.

Engine, Using a Timing Set).

(3) Inspect the check valve collar for grooves

(1) Remove the rocker arm cover.

and scratches. Replace if surfaces cannot be

(2) Install a timing indicator set in the

smoothed with emery cloth.

precombustion chamber of the pump to be tested.

(4) Replace pump plungers and barrels as a

Follow instructions included with the indicator set.

unit.

Disconnect the fuel line to the precombustion

(5) Replace the check valve as a unit.

chamber. Cap or plug openings.

(6) Inspect camshaft cams and camshaft

(3) Move the governor control to the full load

bearings for wear. Replace as necessary.

position.

(7) inspect the control rod for worn notches.

(4) Maintain a 10 to 15 psi fuel pressure with

(8) Replace pump plunger washers which

the fuel priming pump or shop air.

show signs of wear.

CAUTION

(9) Measure pump plungers using a

If shop air is used, connect a relief valve

micrometer. Replace any plunger less than 2.5881

which will release pressure above 15

inches long.

psi. Open the fuel shutoff valve.

5-24