1993 1HDT Fuel Injection Pump Removal (3 Viewers)

[xna0329]

Hello everyone,

My fuel injection pump has developed a leak, and after getting some advice from this forum, it sounds like it’s time for a rebuild. I’ve called 13 shops here in Alaska, and unfortunately, none of them want to work on my rig, so I’m tackling it myself.

I’ve watched several YouTube videos and read through a bunch of forum threads, and here’s where I’m at now. I’d really appreciate it if someone could check my steps and let me know if I’m doing anything wrong:

1. Timing Marks (Photo 1)
   I rotated the crankshaft to align the white paint mark at 12 o’clock. However, I noticed there’s also a TDC mark at about the 9 o’clock position. Should I be aligning to the TDC mark or sticking with the white paint mark?
2. Pump Gear Removal (Photo 2)
   There are 5 nuts on the pump gear that I assume I need to remove. Will the gear want to rotate while I’m trying to loosen them? Is there a specific sequence I should follow?
   I understand I’ll need a puller to remove the gear—can anyone recommend a good puller that’s easy to use? Price isn’t my main concern; I’d rather have something that works smoothly.
3. Pump Mounting Bolts (Photo 3)
   I’ve already removed the fuel lines and disconnected all the hoses. I’ve also loosened two nuts—one circled in red in the photo, and the other on the opposite side. Are there any additional bolts or nuts holding the pump in place that I need to remove before pulling it out?

Thanks in advance for any guidance!

 

[simonliew]

i know if this is your 1st time doing this its nerve racking just like me 20 yrs ago,since then ive done many,to remove the big nut on the pump,you can make a tool using a 2"x1/4' bar,drill 2 M10 holes to bolt to 2 of the 4 holes on the pump and make a cutout for the middle bolt so a socket can get on the big nut,i use a modified power steering puller to remove the pump from the pulley,sometimes the pulley will popout easy and sometimes very hard,theres also a bracket under the back of the pump holding it to the block youve to remove,2 x12mm and one 17mm....im not home now,or i can take pics of the tools i made

 

[xna0329]

i know if this is your 1st time doing this its nerve racking just like me 20 yrs ago,since then ive done many,to remove the big nut on the pump,you can make a tool using a 2"x1/4' bar,drill 2 M10 holes to bolt to 2 of the 4 holes on the pump and make a cutout for the middle bolt so a socket can get on the big nut,i use a modified power steering puller to remove the pump from the pulley,sometimes the pulley will popout easy and sometimes very hard,theres also a bracket under the back of the pump holding it to the block youve to remove,2 x12mm and one 17mm....im not home now,or i can take pics of the tools i made

I loosened the big nut and the two nuts behind the timing case, and the pump just slid off. Did I mess up anything? I thought I needed to remove the big nut, and that there would be a drive gear with an O-ring behind it...

 

[xna0329]

i know if this is your 1st time doing this its nerve racking just like me 20 yrs ago,since then ive done many,to remove the big nut on the pump,you can make a tool using a 2"x1/4' bar,drill 2 M10 holes to bolt to 2 of the 4 holes on the pump and make a cutout for the middle bolt so a socket can get on the big nut,i use a modified power steering puller to remove the pump from the pulley,sometimes the pulley will popout easy and sometimes very hard,theres also a bracket under the back of the pump holding it to the block youve to remove,2 x12mm and one 17mm....im not home now,or i can take pics of the tools i made

I was going to buy a puller, but this thing just slide right out... what did I do wrong...

 

[simonliew]

youre lucky the pump just slide out,was the big nut tight?

 

[xna0329]

youre lucky the pump just slide out,was the big nut tight?

Yes, it was tight... very tight.

 

[mot]

This is something that I've been needing to do (or done).

Mine seems to drip fuel when the ambient temperature is cold, and no problem when outside temp is warm (or hot).

Keep up the great work!

Mot