240 L6-2383cc 2.4L DSL SOHC D24 FI (1982)
Diesel MFI Pump: Service and Repair
Fig. 1 Engine at TDC and injection
Fig. 10 Alignment of injection pump marks
1.
Clamp and disconnect hoses at cold start device. Disconnect accelerator cable, kickdown cable, if equipped, and wire at stop valve.
2.
Remove rear timing belt cover, clean and disconnect fuel line connections at injection pump. Plug open connections to prevent entry of dirt.
3.
Remove vacuum pump and plunger. Clean and remove fuel delivery pipes and plug all connections to prevent entry of dirt.
4.
Turn engine to No. 1 cylinder TDC and injection, Fig. 1. With flywheel mark at zero (0), pump sprocket notch must be aligned with mark on
bracket and pump, Fig. 10.
5.
Loosen injection pump bracket bolts and remove pump belt.
6.
Remove camshaft rear sprocket using wrench 5199 or equivalent to hold gear, and wrench 5201 to loosen sprocket center nut. Do not allow
camshaft to rotate, sprocket should rotate on camshaft.
7.
Lock injection pump sprocket with stop 5193 or equivalent and using wrench 5201 or equivalent remove sprocket nut. Use puller 5204 or
equivalent to remove sprocket.
8.
Remove injection pump bracket bolts and remove pump with bracket. Remove Allen head bolts and separate pump from bracket.
9.
Install new pump so mark on pump body aligns with mark on bracket. Install pump sprocket making sure that shaft key is correctly installed.
10.
Refer to ``Injection Pump Setting'' procedure and set pump.
11.
Fill pump with fuel if necessary and install rear timing belt cover.
12.
Connect fuel supply and return lines. Do not switch connector screws. Screw for fuel return line has small hole and is marked OUT. Torque to 18
ft. lbs. (25 Nm).
13.
Install fuel delivery pipes and torque cap nuts to 18 ft. lbs. (25 Nm). Install vacuum pump and plunger.
14.
Connect cold start device hoses, stop valve wires, accelerator cable, and kickdown cable on automatic transmission models.
