5-101.

bk Page 66 Friday, March 17, 2006 11:05 AM

200 ENGINE ASSEMBLY

[221 CD] ECONOVANCE [221 GP] FUEL INJECTION
PUMP
Installation
Refer to Figure 6-76.
Installation
1. Lubricate with clean engine oil and then This procedure is described and illustrated with
install O-ring in groove on front of pump-to-Econovance adapter installed on pump.
Econovance assembly (5).
2. Position the Econovance assembly (5) on To install the fuel injection pump:
the mounting surface of the engine front 1. Install two J 39732 alignment dowels in the
flange. You may have to rotate the Econovance housing. Install a new injection
Econovance shaft to clear the camshaft pump adapter housing to Econovance
gear. gasket over the alignment dowels.
3. Install the four capscrews (4) securing the
assembly to the front flange. Torque to
40 lb-ft (54 N폷m) using torque wrench
J 24407 or equivalent. Check for binding. J 39732
4. Slide the drive coupling (3) into the splines
(6) of the shaft (pre-1992 style shown).
5. Install the fuel injection pump adapter (2)
and gasket (not shown) on the Econovance
housing (5). Torque the mounting capscrews
(1) to 40 lb-ft (54 N폷m).

200440a

For installation of the fuel injection pump drive

gear, refer to Injection Pump Fixed-Timing Figure 6-77 — Installing Alignment Dowels
procedure found in the SETUP AND
ADJUSTMENTS section.

Install the outer coupling on the Econovance

4 5
3 mating gear prior to fuel injection pump
2
installation. This will prevent the outer coupling
from dropping off if installed on the pump prior to
1 installation.

6
200364a

Figure 6-76 — Econovance Housing Installation

(Pre-1992 Style Shown)

1. Mounting capscrew 4. Capscrew

2. Injection pump adapter 5. Econovance
3. Drive coupling 6. Splines

Page 6-66
5-101.bk Page 67 Friday, March 17, 2006 11:05 AM

200 ENGINE ASSEMBLY

3. Loosen the two upper support bracket-to-
fuel injection pump capscrews.

200441a

Figure 6-78 — Installing Outer Coupling 200443a

2. Loosen the three injection pump rear Figure 6-80 — Outer Upper Support Capscrew
support bracket-to-cylinder block capscrews.
Then hand tighten the capscrews until snug,
and loosen 1/4 turn. The lower support
bracket should move freely from side to side.

200444a

Figure 6-81 — Inner Upper Support Capscrew

4. Align and slide the fuel injection pump and

adapter over the two alignment dowels.

200442a

Figure 6-79 — Lower Support Bracket Adjustment

200445a

Figure 6-82 — Aligning Pump Over Dowels

Page 6-67
5-101.bk Page 68 Friday, March 17, 2006 11:05 AM

200 ENGINE ASSEMBLY

5. With the fuel injection pump positioned over 7. Install and torque the remaining fuel
the alignment dowels, in one motion, lift the injection pump adapter mounting capscrews
rear of the pump and slightly rotate the to 40 lb-ft (54 N폷m) using torque wrench
Econovance hub. Slide the pump forward J 24407 or equivalent.
into position.
8. Install and torque the two link-to-support
capscrews to 40 lb-ft (54 N폷m) using torque
wrench J 24407 or equivalent.

200446a

Figure 6-83 — Rotating Hub

6. To secure fuel injection pump, install the

lower pump adapter mounting capscrew and
then remove the alignment dowels.

200449a

Figure 6-85 — Torquing Link Capscrews

200447a

Figure 6-84 — Securing Fuel Injection Pump

Page 6-68
5-101.bk Page 69 Friday, March 17, 2006 11:05 AM

200 ENGINE ASSEMBLY

9. Torque the three lower support bracket-to- 10. Torque the two upper support bracket-to-fuel
cylinder block capscrews to 40 lb-ft injection pump capscrews to 15 lb-ft
(54 N폷m) using torque wrench J 24407 or (20 N폷m) using torque wrench J 24407 or
equivalent. equivalent. Loosen and then retorque the
capscrews to 40 lb-ft (54 N폷m).

200450a
200451a
Figure 6-86 — Support Bracket-to-Cylinder Block
Capscrews Figure 6-87 — Torquing Upper Support Bracket-to-Fuel
Injection Pump Capscrews

11. Loosen the two link-to-support capscrews at

least two full turns. Then retorque link-to-
support capscrews to specification.

Refer to Section 7, SETUP AND ADJUSTMENTS,

Fuel Injection Fixed-Timing procedure, for steps to
be used in setting fuel injection pump-to-engine
timing.

Page 6-69
5-101.bk Page 70 Friday, March 17, 2006 11:05 AM

200 ENGINE ASSEMBLY

[222 KD] FUEL NOZZLE INLET 5. Tighten all fuel inlet tube assembly clamping
screws to 35 lb-ft (48 N폷m) torque using
TUBE ASSEMBLY torque wrench J 24407 or equivalent.

Installation
Refer to Figure 6-88.
An open-ended “crow’s foot” adapter is required
1. Install the fuel nozzle inlet tube assemblies with the torque wrench for installation of nozzle
(1) into the front and rear cylinder heads. fuel inlet tube assemblies. Avoid twisting the lines
Lubricate the nozzle inlet tube clamping when tightening the sleeve nuts.
screw threads before installing.
2. Install the tube assemblies until light contact 6. While holding the fuel inlet tube assembly
is made with the nozzle holders. Lightly clamping screws, tighten the tube sleeve
tighten the clamping screws and then lightly nuts (1) at the cylinder heads to 25 lb-ft
tighten the fuel inlet tube sleeve nuts (1). (34 N폷m) torque using torque wrench
3. Connect the injection pump end of the fuel J 24407 or equivalent
tubes to the appropriate fuel injection pump 7. Tighten all fuel inlet tube sleeve nuts (6)
outlet ports and lightly tighten the sleeve located at the fuel injection pump outlet ports
nuts (6). to 25 lb-ft (34 N폷m) torque using torque
4. Install and lightly tighten the fuel inlet tube wrench J 24407 or equivalent.
insulators and clamp plate and brackets (3). 8. Tighten all fuel inlet tube insulators and
clamp plates and brackets.

These tube insulators and clamp plates and

brackets are required to prevent cavitation
erosion and vibration failure of the tubes.

Page 6-70
5-101.bk Page 71 Friday, March 17, 2006 11:05 AM

200 ENGINE ASSEMBLY

2 1 3 2 1
3
1

11

4
5

10

9
5 6
8
7
200353a

Figure 6-88 — Fuel Nozzle Inlet Tube Assembly Installation

1. Nozzle fuel inlet tube and sleeve nut 7. Oil filler feed tube
2. Rear fuel inlet tube assembly 8. Oil filler feed tube bracket
3. Bracket/insulator (tube clamp) 9. Capscrew
4. Front fuel inlet tube assembly 10. Exhaust manifold
5. Bracket/insulator (tube clamp) 11. Capscrew
6. Sleeve nut

Page 6-71
5-101.bk Page 13 Friday, March 17, 2006 11:05 AM

200 SETUP AND ADJUSTMENTS

Accurately setting the injection pump timing is the Thoroughly clean all residue from the fixed timing
best way to ensure optimum fuel economy, port threads (timing access window) before
engine durability, and maintain engine exhaust installing tool sensor. This will prevent the
within established EPA limits. possibility of a false reading.

2. Clean all residue from the TEM sensor or

Special Tools Required plug threads.
앫 Fixed Timing Position Sensor (Light)
J 37077
앫 Alignment Fixture J 37078
앫 Pump Drive Gear Alignment Dowels
J 37085
앫 Hub Rotation Tool J 38740

Setting Static Fuel Injection Pump

Timing
To set the static fuel injection pump timing, prior
to pump removal, proceed as follows:
1. Remove the TEM sensor (on mechanically Figure 7-15 — Cleaning TEM Sensor Threads
governed engines, remove plug) from the
fixed timing port.

Figure 7-14 — Removing TEM Sensor

Page 7-13
5-101.bk Page 14 Friday, March 17, 2006 11:05 AM

200 SETUP AND ADJUSTMENTS

3. Clean the J 37077 tool sensor probe points
with compressed air before using. This helps
prevent metallic contamination between the
sensor probe points.

J 37077

200405a

Figure 7-17 — Installing J 37077 Tool

5. Slowly turn the knurled surface clockwise to

lock the tool into place. Check to make sure
tool is seated by applying pressure to the
end of the tool and checking for any
movement. If movement is detected, remove
and reinstall the tool.

200406a

Figure 7-18 — Turning Knurled Surface Clockwise

6. Connect the fixed timing tool ground to the

200492a engine and press power switch on.
Figure 7-16 — Cleaning Sensor Probe Points

4. Install fixed timing position sensor tool

J 37077. Make sure that tool is correctly
aligned with the locating groove in the fixed
timing port.

J3
70
77
PO
PO W
ER
SIT
IO
N
A SE
NS
KE OR
NT
-M B
OO
RE
200407a

Figure 7-19 — Grounding and Turning Tool On

Page 7-14
5-101.bk Page 15 Friday, March 17, 2006 11:05 AM

200 SETUP AND ADJUSTMENTS

7. To continue the procedures for setting the Fuel Injection Pump Driven Gear
timing, refer to the following applications for
an engine with front timing indicator or with
Installation
rear timing indicator. To install the fuel injection pump gear:
ENGINE WITH FRONT TIMING INDICATOR 1. Verify crankshaft is set to correct BTDC
position for pump timing.
E7 mechanically governed engines with
automatic transmissions use the Center Web 2. Connect timing-light tool J 37077 (refer to
Vibration Damper with timing marks. The beginning of the section, Setting Static Fuel
vibration damper timing indicator and engine front Injection Pump Timing). Using hub rotation
turnover bracket are used in this application. tool J 38740, rotate the timing gear hub
clockwise until both lights A and B are lit.
1. Rotate the engine crankshaft counterclock-
wise (as viewed from the front of the engine)
to a minimum of 45 degrees before Top
Dead Center (TDC).
2. Rotate the engine crankshaft clockwise until
lamps A and B are both lit. Fuel injection J 37077

pump-to-engine timing is now set and the J 38740

injection pump can be removed from the POWER

engine. POSITION SENSOR

A B

ENGINE WITH REAR TIMING INDICATOR KENT-MOORE

E7 mechanically governed engines with manual

transmissions and all V-MAC engines with 200452a
manual and automatic transmissions use the
flatback vibration damper with no timing marks. Figure 7-20 — Rotating Timing Gear Hub Clockwise
They are also equipped with flywheel and
flywheel housings that incorporate engine timing
and turnover features. With rear timing, the front
timing indicator and engine front turnover bracket 앫 Use the proper hub rotation tool J 38740
are not utilized. which allows rotation of the hub only.
1. Remove all six 8-mm capscrews to access 앫 Do not use the inner shaft nut (25 mm) to
the flywheel housing timing window. rotate the timing gear hub.
2. Remove the plastic plug in the cast- 앫 If the inner shaft nut is used to rotate the hub,
machined opening in the forward face of the the nut may loosen, resulting in subsequent
housing. failure.
3. Insert engine barring socket tool J 38587
into the opening.
4. Install a 1/2-inch drive ratchet into tool
J 38587 to rotate the flywheel.
5. Rotate the flywheel counterclockwise to a
minimum of 45 degrees before TDC.
6. Rotate the flywheel clockwise in normal
direction (as viewed from the front of the
engine), until lamps A and B are both lit.
Fuel injection pump-to-engine timing is now
set and the injection pump can be removed
from the engine. Remove tool J 38587 from
the flywheel housing.

Page 7-15
5-101.bk Page 16 Friday, March 17, 2006 11:05 AM

200 SETUP AND ADJUSTMENTS

3. Install two pump drive gear alignment 5. Install two driven gear capscrews in the
dowels, J 37085, to ease alignment of drive open holes. Install capscrews snugly to
gear to timing gear hub. remove clearance but allow relative motion
between hub and gear.

J 37085

200453a 200455a

Figure 7-21 — Installing Drive Alignment Dowels Figure 7-23 — Installing Driven Gear Capscrews

4. Install the fuel injection pump driven gear on 6. Remove the alignment dowels and install
the timing gear hub so the screw holes in the remaining capscrews in the same manner.
hub are centered in the gear slots/alignment
dowels. 7. Using hub rotation tool J 38740, rotate the
timing gear hub counterclockwise until
screws bottom in the ends of the gear slots
in the fuel injection pump driven gear. When
this happens, both lamps will go out.

Three different head sizes have been used for

the injection pump timing adjustment capscrews.
Refer to Description at the beginning of this
procedure for additional information.

200454a

Figure 7-22 — Installing Driven Gear

Page 7-16
5-101.bk Page 17 Friday, March 17, 2006 11:05 AM

200 SETUP AND ADJUSTMENTS

J 38740

7
707
J3

R
WE
PO
OR
NS
SE
ION
SIT
PO B
A RE
OO
-M
NT
KE

200458a

Figure 7-24 — Rotating Timing Gear Hub

Counterclockwise

8. Rotate timing gear hub clockwise until both

A and B lamps are lit. There is only a very
small band of rotation for which both lamps
are lit.

200460a

J 37077
Figure 7-26 — Torquing Driven Gear Capscrews
POWER

POSITION SENSOR

A B
KENT-MOORE

Lamp A or B may go out during torquing

procedure. This is acceptable. Do not attempt to
keep lamps lit. Doing so may cause improper
pump-to-engine timing.
200459a

Figure 7-25 — Rotating Timing Gear Hub Clockwise

9. Torque all fuel injection pump driven gear

capscrews to 40 lb-ft (54 N폷m) using torque
wrench J 24407 or equivalent.

Page 7-17
5-101.bk Page 18 Friday, March 17, 2006 11:05 AM

200 SETUP AND ADJUSTMENTS

Checking Pump-to-Engine Timing Fuel Injection Pump Access Cover
Installation
To install the fuel injection pump access cover:
Using hub bolt to rotate engine backward may 1. Lubricate the access cover O-ring with
change bolt torque. Check torque of hub bolt after Lubrizol OS-50044 or equivalent.
completing timing procedure.

1. Rotate engine crankshaft counterclockwise

to a minimum of 45 degrees before TDC.
Both A and B lamps will go out.
2. Rotate engine crankshaft clockwise until
both A and B lamps are lit. If timing pointer
does not cover a value within ± 0.5 (1/2)
degree of desired timing, the engine is not
timed correctly. Before continuing, check
and verify piston is at TDC. Refer to
Locating Piston Top Dead Center (TDC) in
SETUP AND ADJUSTMENTS.
200461a

Figure 7-27 — Lubricating Access Cover O-Ring

If timing is not within specification, reset and 2. Install clamp and access cover capscrews.
recheck timing.
3. Torque access cover capscrews to 30 lb-ft
(41 N폷m) using torque wrench J 24407 or
3. After achieving correct timing, remove timing equivalent.
tools.
a. Turn tester power off.
b. Disconnect tester ground.
c. Remove fixed timing probe.
4. Install fixed timing port plug or TEM sensor.
5. Check torque of hub bolt. The correct torque
is 360 lb-ft (488 N•m).

200463a

Figure 7-28 — Installing and Torquing Access Cover

Capscrews

4. Run wire through both the drilled access

cover capscrews and through the center of
the lead seal and loop it. Then bring it
through again.

Page 7-18
5-101.bk Page 19 Friday, March 17, 2006 11:05 AM

200 SETUP AND ADJUSTMENTS

200465a

Figure 7-29 — Installing Access Cover Seal Figure 7-31 — P7100 Injection Pump/Mechanical
Governor Pre-Lubrication
5. Using Midget sealing tool 814 or equivalent,
compress the lead seal. To pre-lubricate the P7100 V-MAC fuel injection
6. Reconnect fuel injection pump oil supply pump and governor, remove the timing event
line. marker located on the governor and add
3.5 ounces (104 ml) of clean engine oil. Reinstall
the timing event marker. To pre-lubricate the
Fuel Injection Pump Pre-Lubrication V-MAC injection pump, remove the plug in the
side of the pump housing and add 11 ounces of
To pre-lubricate the P8500/RE30 fuel injection clean engine oil. Reinstall the plug.
pump and governor, add 12 ounces (0.4 liter) of
clean engine oil through the Timing Event Marker
(TEM) port located in the RE30 governor
housing. Oil will run through the governor into the
pump.

TEM PORT Figure 7-32 — P7100 V-MAC Injection Pump/Governor

Pre-Lubrication

200466a

Figure 7-30 — P8500/RE30 Injection Pump

Pre-Lubrication
Pre-lubrication is required anytime a new or used
To pre-lubricate the P7100 fuel injection pump fuel injection pump is removed and then installed
with mechanical governor, remove the timing on the engine.
sensor (fixing plate) plug in the governor housing.
Add 12 ounces (355 ml) of clean engine oil. This
will fill both the governor and fuel injection pump.
Reinstall the timing sensor (fixing plate) plug.

Page 7-19
5-101.bk Page 20 Friday, March 17, 2006 11:05 AM

200 SETUP AND ADJUSTMENTS

Timing Event Marker (TEM)
Installation
To install the TEM:
1. Thoroughly clean all oil residue from the
TEM and timing access window.
2. Completely back off the TEM jam nut
(toward the sensor pigtail).
3. Apply a 1/8- to 1/4-inch bead of Silastic
(MACK part No. 342SX32 or equivalent)
around the sensor threads at the jam nut.

Figure 7-35 — Torquing TEM Sensor Jam Nut

APPLY 7. Wipe the excess Silastic with a dry cloth.

1/8–1/4 INCH
BEAD OF 8. Reconnect all brackets, connections and
SILASTIC fuel lines.

2
1

205205a

Figure 7-33 — Silastic Application

4. Install the TEM sensor into the timing access

window and hand tighten until seated in the
timing window.

3
5 4
9 8 6
7

200363a

Figure 7-36 — Pump Line Connections

1. Return from secondary 5. Return to secondary filter

filter 6. Return from primary filter
Figure 7-34 — Installing TEM Sensor 2. Cylinder head overflow 7. Lubrication supply line
line 8. Capscrew
5. Tighten the jam nut, running it over the 3. Return to tank line 9. Capscrew
Silastic. 4. Capscrew

6. Torque the jam nut to 22 lb-ft (30 N폷m) using

9. Check all connections and clamps for
torque wrench J 24406 or equivalent.
tightness. Check for leaks.

Page 7-20