Engine Maintenance 9-28
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.
3. Remove the old injection pump. Use the injection pump gear tool (P/N: See tool Catalogue) to remove injection pump gear
without removing timing gear cover.
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 factory-set timing
and the EPA certification would void.
4. Record the injection angle marked on the old injection pump. 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. (sample: number 67 equals an injection angle of 6.7 degrees.
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 from the new injection pump.
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. Tighten the injection pump mounting nuts when
the index mark is aligned as necessary with the injection angle sticker.
8. Install the injection pump gear, lock washer, and nut. torque the nut to 78 to 88 Nm.
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. It helps to install the idler gear last when aligning the timing marks.
Index Marks Location – TK 486V Engines
1. Index Marks
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
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