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Home >> Chevrolet >> 1983 >> Chevette Base, 2D Hatchback, 1.8 D, Automatic >> Repair and Diagnosis >> Engine Performance >> System >> Fuel Injection System - 4-CYL Diesel >> Removal & Installation >> Injection Pump >> Installation

Injection Pump: Installation

  1. Install injection pump, tightening 4 mounting bolts in sequence shown. See Fig 1 . No clearance should exist between rear bracket and injection pump bracket.
    Fig 1: Tightening Sequence for Injection Pump No clearance should exist between rear bracket and pump bracket.
    G625
  2. Install injection pump pulley by aligning it with key groove. Align mark on gear with mark on front plate. See Fig 2 . Tighten nut using an 8 mm by 1.25" lock bolt to prevent turning pulley. Remove cam cover.
    Fig 2: Aligning Marks For Injection Pump Gear
    G626
  3. With No. 1 piston at TDC, install Fixing Plate (J-29761) to slot in rear of camshaft to prevent camshaft from rotating. Remove camshaft gear attaching bolt.
  4. Using Puller (J-22888), remove cam gear. Reinstall cam gear loosely so it can be turned by hand. Install the timing belt noting that the belt should be properly tensioned between pulleys, cogs on belt and pulley should be engaged properly, crankshaft should not be turned and timing belt looseness should be concentrated on tension pulley.
  5. Depress tension pulley with finger and install tension spring. Loosely tighten tension pulley bolts, tightening top bolt first to prevent movement of pulley. Tighten camshaft pulley bolt. Remove injection pump gear lock bolt.
  6. Remove fixing plate on end of camshaft. Check that No. 1 piston is at TDC. DO NOT  turn crankshaft in attempt to make adjustment. Check that injection pump pulley mark is in line with mark on plate.
  7. Fixing plate should fit smoothly into slot at rear of camshaft. Remove fixing plate. Loosen tensioner pulley and plate bolts. Concentrate looseness on tensioner then tighten bolts in sequence shown. See Fig 3 . Belt tension should be checked at a point between camshaft gear and injection pump gear.
    Fig 3: Tensioner Bolt Tightening Sequence Check belt tension between camshaft gear and injection pump gear.
    G627
  8. Insure that No. 1 piston is at TDC. Check that timing belt is properly tensioned and that marks are aligned.
  9. Remove distributor head screw and washer. Install static Timing Gauge (J-29763) with lift approximately .04" (1 mm) from plunger. Bring No. 1 piston to a point 45-60° before TDC by turning crankshaft. Turn dial indicator on timing gauge to zero.
    Fig 4: Damper Pulley Alignment Notches Only the group of 4 notches are used for static timing.
    G628
  10. The damper pulley has a series of notched lines on it. There are 4 notches on one side and 7 on the other. The 4 lines are used for static timing. Turn crankshaft until the 18° line is in alignment with pointer on dial indicator. Read dial indicator.
  11. Standard reading should be .02" (.5 mm). Turn crankshaft in normal direction of rotation. If reading on dial indicator deviates from specified range, hold crankshaft at 18° position and loosen 2 nuts on injection pump flange.
    Fig 5: Static Timing Setting Dial indicator reading should be .02" (.5 mm).
    G629
  12. Move injection pump to a point where proper dial indicator reading is reached and tighten pump flange nuts. Recheck reading and adjust as necessary.
  13. Install distributor screw and washer in injection pump. Install cam cover, fuel injection lines and fuel filter. Connect necessary lines and hoses and install upper dust cover.
  14. Install coolant recovery bottle, radiator and fan shroud. Fill radiator with coolant. Adjust idle speeds.
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