fabjunkie
1/2 ton status
Got the injection pump in this weekend. Spent the afternoon yesterday pulling it. It took 3 or 4 hours, but a lot of that time was wasted. First things first, I went to put the barring tool in (**** just remembered I never put the plug back in and it was sitting on the leaf spring 
) and it would not go in far enough to engage the flywheel. Stuck my finger in the hole and the damn bellhousing that came with this tranny is cast in the way of the barring tool. Ending up using the alternator to turn the motor over.
I spent at least a half hour trying to find TDC with the pin. Never could get it to go into anything. Finally I checked the angle of the pump on the truck, matched the new pump to that, and checked the angle of the key in the shaft. I then eyeballed where the key should be on the truck, locked the pump down, pulled it, and prayed that it was close. I sure am glad that I bought that special wrench. It made what I'm sure is a nightmare without it easy. The bottom nut on the pump came almost all the way off and then pulled the stud out with it. So I cleaned up all three this morning.
New pump keyway position
Old pump keyway position.
Backside of the timing case where the pump bolts to.
This morning I installed the gov spring, swapped the fuel pin from the old pump, and matched up all the screw settings. Checked where the shaft key was and it was as close as I could have gotten it by eye. Went to slide the pump on and it went right in. Everything else went right back together and I was done within the hour.
Turned the key on to bleed the system with the in-tank pump and discovered the passenger side pump is dead. Switched tanks and bled out up to the filter, then the return line on the pump. I left all the injector lines loose at the injector. Cranked the motor a few times for 20-30 seconds and there was diesel everywhere. Tightened them all up and it fired up as fast as I could hit the key. Loosened and tightened each one to make sure they were bled and none of them needed any more bleeding.
HOLY FOCK is this thing quick now. The spring is great and made it much more drivable. I don't know what made such a difference, but this is a different truck. I guess the old pump was just that worn out and having the rebuilt one did it. The full fuel screw is at the stock spot. All that is done is the spring and fuel pin. I bumped the timing as much as I could but could only get a little over a 1/16". It smokes a lot more than it used to, so much that I may have to turn the AFC down a little. I need to play with the tuning a bit yet, and I'll probably turn the fuel up a little. I spent an hour this afternoon just running around, went to the car wash and cleaned undercarriage, underhood, and the outside. It sure feels good to be driving it again.
Next is to finish the exhaust, get the front drive shaft built, and mount the intercooler. First though I need to plug this hole.
) and it would not go in far enough to engage the flywheel. Stuck my finger in the hole and the damn bellhousing that came with this tranny is cast in the way of the barring tool. Ending up using the alternator to turn the motor over.
I spent at least a half hour trying to find TDC with the pin. Never could get it to go into anything. Finally I checked the angle of the pump on the truck, matched the new pump to that, and checked the angle of the key in the shaft. I then eyeballed where the key should be on the truck, locked the pump down, pulled it, and prayed that it was close. I sure am glad that I bought that special wrench. It made what I'm sure is a nightmare without it easy. The bottom nut on the pump came almost all the way off and then pulled the stud out with it. So I cleaned up all three this morning.
New pump keyway position
Old pump keyway position.
Backside of the timing case where the pump bolts to.
This morning I installed the gov spring, swapped the fuel pin from the old pump, and matched up all the screw settings. Checked where the shaft key was and it was as close as I could have gotten it by eye. Went to slide the pump on and it went right in. Everything else went right back together and I was done within the hour.
Turned the key on to bleed the system with the in-tank pump and discovered the passenger side pump is dead. Switched tanks and bled out up to the filter, then the return line on the pump. I left all the injector lines loose at the injector. Cranked the motor a few times for 20-30 seconds and there was diesel everywhere. Tightened them all up and it fired up as fast as I could hit the key. Loosened and tightened each one to make sure they were bled and none of them needed any more bleeding.
HOLY FOCK is this thing quick now. The spring is great and made it much more drivable. I don't know what made such a difference, but this is a different truck. I guess the old pump was just that worn out and having the rebuilt one did it. The full fuel screw is at the stock spot. All that is done is the spring and fuel pin. I bumped the timing as much as I could but could only get a little over a 1/16". It smokes a lot more than it used to, so much that I may have to turn the AFC down a little. I need to play with the tuning a bit yet, and I'll probably turn the fuel up a little. I spent an hour this afternoon just running around, went to the car wash and cleaned undercarriage, underhood, and the outside. It sure feels good to be driving it again.
Next is to finish the exhaust, get the front drive shaft built, and mount the intercooler. First though I need to plug this hole.
, glad to see it went "semi smooth" 
. I always forget how much physically smaller the vp's are compared to the p pumps. 
