Tips on installing new Fuel Injection Pump

[Craig Almaguer]

So, I now have a new fuel injection pump that I am going to attempt to install tomorrow morning. It started raining and I had to stop, right now. I’ve got top dead center found, the pin, or in my case a 3/8 drillbit is in place and “secured.” All hoses and bolts are disconnected and the old fuel injection pump is loose and ready to come out. HOWEVER, as most know, this is where problems can occur. I don’t have the injection pump tool kit to secure the pulley and position as I pull the old pump off. I am considering fabricating a piece of stock with a couple of threaded holes to insert …and bolt down/secure, before removing the old IP.

Do any of you all have tips for this? Can it be done without the tool? I know things can slip around and that’s the danger. Has anyone done it without the tool and just the pin (drill bit)?

Thanks again for all your input!

Craig
‘96 D110 300 TDi

 

[JimC]

If you pull the pump off you have to re-time because there is no way to hold the pulley in position while it is unbolted from the pump. You can’t get the pump out without removing the pulley. Additionally, the pump in the proper engine resting position (TDC) is ”on-cam“ and the shaft will spring back to pump-neutral position as soon as the pulley is loosened. You need the dial gauge set to get the pump back on cam before tightening the pulley. I guess some old grognard could do it by feel, but the difference between good, rough running, and no-start is thousandths.