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Diagnosis and repair



REMOVAL

1.Disconnect ground cables from both batteries.
2.Remove engine cover (Econoline only).
3.Remove air cleaner and install intake opening cover, Intake Manifold Cover T83T-9424-A.
4.Remove injection pump.

{tag}286436333@


5.Remove bolts attaching injection pump drive gear cover to engine block, and remove cover.

NOTE: Do not remove drive gear yet.


6.Remove glow plugs with Glow Plug Socket D83T-6002-A or equivalent to facilitate turning engine over by hand.
7.Turn engine over by hand to TDC (top dead center), compression stroke of No.1 piston.


NOTE: To determine that No.1 piston is at TDC (compression stroke), position injection pump drive gear dowel at the four oclock position. The scribe line in vibration damper should be at TDC.

NOTE: To aid aligning the timing marks, the pump drive gear and the camshaft gear are marked with "Y" timing marks. The crankshaft and camshaft gears are marked with "0" (dot) alignment marks. With engine at TDC compression for No.1 cylinder, the "Y" marks should be aligned.


{tag}286441517@



CAUTION: Do not remove injection pump gear without performing the following procedure.

8.Slide injection pump gear back (do not remove) to expose top of camshaft gear when looking down into the front cover. In addition to the "Y", the gear teeth adjacent to the "Y" on the camshaft gear are permanently dyed.
9.Remove injection pump drive gear.



INSTALLATION


1.Clean all gasket and sealing surfaces with a suitable solvent and dry thoroughly.

NOTE: To determine that No.1 piston is at TDC of compression stroke, position injection pump drive gear dowel at the four oclock position. The scribe line in vibration damper should be at TDC.

2.With drawn line on drive gear at six oclock position, install gear and align all drive gear timing marks.


CAUTION: Use extreme care to avoid disturbing injection pump drive gear, once it is in position.

3.Apply a 3.16mm (1/8 inch) bead of Silicone Rubber Sealant D6AZ-1 9562-BA (ESB-M4G92-A) or equivalent along bottom surface of injection pump drive gear cover.


NOTE: When applying Silicone Rubber Sealant D6AZ-1 9562-BA (ESB-M4G92-A) or equivalent always use the bead size specified and join the components within 15 minutes of application. After 15 minutes, sealant begins to set-up and sealing effectiveness may be reduced.

4.Install injection pump drive gear cover and tighten retaining bolts to 19 Nm (14 ft-lb). Apply Perfect Seal Sealing Compound B5A-1 9554-A (ESR-M18P2-A) or equivalent to bolt threads before assembly.

NOTE: With injection pump drive gear cover installed, the injection pump drive gear cannot "jump" timing.

5.Remove intake manifold cover and install air cleaner.
6.Install ground cables to both batteries.


NOTE: On vehicles equipped with EEC, when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.

7.Run engine and check for oil, fuel and coolant leaks.


WARNING: KEEP EYES AND HANDS AWAY FROM NOZZLE SPRAY. FUEL SPRAYING FROM THE NOZZLE UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.


8.If necessary, purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until bubble-free fuel flows from connection.
9.Install engine cover (E-250-350 only).

REMOVAL

1.Disconnect ground cables from both batteries.
2.Remove engine cover (Econoline only).
3.Remove air cleaner and install intake opening cover, Intake Manifold Cover T83T-9424-A.
4.Remove injection pump.





5.Remove bolts attaching injection pump drive gear cover to engine block, and remove cover.

NOTE: Do not remove drive gear yet.


6.Remove glow plugs with Glow Plug Socket D83T-6002-A or equivalent to facilitate turning engine over by hand.
7.Turn engine over by hand to TDC (top dead center), compression stroke of No.1 piston.


NOTE: To determine that No.1 piston is at TDC (compression stroke), position injection pump drive gear dowel at the four oclock position. The scribe line in vibration damper should be at TDC.

NOTE: To aid aligning the timing marks, the pump drive gear and the camshaft gear are marked with "Y" timing marks. The crankshaft and camshaft gears are marked with "0" (dot) alignment marks. With engine at TDC compression for No.1 cylinder, the "Y" marks should be aligned.


{tag}286441517@



CAUTION: Do not remove injection pump gear without performing the following procedure.

8.Slide injection pump gear back (do not remove) to expose top of camshaft gear when looking down into the front cover. In addition to the "Y", the gear teeth adjacent to the "Y" on the camshaft gear are permanently dyed.
9.Remove injection pump drive gear.



INSTALLATION


1.Clean all gasket and sealing surfaces with a suitable solvent and dry thoroughly.

NOTE: To determine that No.1 piston is at TDC of compression stroke, position injection pump drive gear dowel at the four oclock position. The scribe line in vibration damper should be at TDC.

2.With drawn line on drive gear at six oclock position, install gear and align all drive gear timing marks.


CAUTION: Use extreme care to avoid disturbing injection pump drive gear, once it is in position.

3.Apply a 3.16mm (1/8 inch) bead of Silicone Rubber Sealant D6AZ-1 9562-BA (ESB-M4G92-A) or equivalent along bottom surface of injection pump drive gear cover.


NOTE: When applying Silicone Rubber Sealant D6AZ-1 9562-BA (ESB-M4G92-A) or equivalent always use the bead size specified and join the components within 15 minutes of application. After 15 minutes, sealant begins to set-up and sealing effectiveness may be reduced.

4.Install injection pump drive gear cover and tighten retaining bolts to 19 Nm (14 ft-lb). Apply Perfect Seal Sealing Compound B5A-1 9554-A (ESR-M18P2-A) or equivalent to bolt threads before assembly.

NOTE: With injection pump drive gear cover installed, the injection pump drive gear cannot "jump" timing.

5.Remove intake manifold cover and install air cleaner.
6.Install ground cables to both batteries.


NOTE: On vehicles equipped with EEC, when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.

7.Run engine and check for oil, fuel and coolant leaks.


WARNING: KEEP EYES AND HANDS AWAY FROM NOZZLE SPRAY. FUEL SPRAYING FROM THE NOZZLE UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.


8.If necessary, purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until bubble-free fuel flows from connection.
9.Install engine cover (E-250-350 only).

REMOVAL

1.Disconnect ground cables from both batteries.
2.Remove engine cover (Econoline only).
3.Remove air cleaner and install intake opening cover, Intake Manifold Cover T83T-9424-A.
4.Remove injection pump.

{tag}286436333@


5.Remove bolts attaching injection pump drive gear cover to engine block, and remove cover.

NOTE: Do not remove drive gear yet.


6.Remove glow plugs with Glow Plug Socket D83T-6002-A or equivalent to facilitate turning engine over by hand.
7.Turn engine over by hand to TDC (top dead center), compression stroke of No.1 piston.


NOTE: To determine that No.1 piston is at TDC (compression stroke), position injection pump drive gear dowel at the four oclock position. The scribe line in vibration damper should be at TDC.

NOTE: To aid aligning the timing marks, the pump drive gear and the camshaft gear are marked with "Y" timing marks. The crankshaft and camshaft gears are marked with "0" (dot) alignment marks. With engine at TDC compression for No.1 cylinder, the "Y" marks should be aligned.







CAUTION: Do not remove injection pump gear without performing the following procedure.

8.Slide injection pump gear back (do not remove) to expose top of camshaft gear when looking down into the front cover. In addition to the "Y", the gear teeth adjacent to the "Y" on the camshaft gear are permanently dyed.
9.Remove injection pump drive gear.



INSTALLATION


1.Clean all gasket and sealing surfaces with a suitable solvent and dry thoroughly.

NOTE: To determine that No.1 piston is at TDC of compression stroke, position injection pump drive gear dowel at the four oclock position. The scribe line in vibration damper should be at TDC.

2.With drawn line on drive gear at six oclock position, install gear and align all drive gear timing marks.


CAUTION: Use extreme care to avoid disturbing injection pump drive gear, once it is in position.

3.Apply a 3.16mm (1/8 inch) bead of Silicone Rubber Sealant D6AZ-1 9562-BA (ESB-M4G92-A) or equivalent along bottom surface of injection pump drive gear cover.


NOTE: When applying Silicone Rubber Sealant D6AZ-1 9562-BA (ESB-M4G92-A) or equivalent always use the bead size specified and join the components within 15 minutes of application. After 15 minutes, sealant begins to set-up and sealing effectiveness may be reduced.

4.Install injection pump drive gear cover and tighten retaining bolts to 19 Nm (14 ft-lb). Apply Perfect Seal Sealing Compound B5A-1 9554-A (ESR-M18P2-A) or equivalent to bolt threads before assembly.

NOTE: With injection pump drive gear cover installed, the injection pump drive gear cannot "jump" timing.

5.Remove intake manifold cover and install air cleaner.
6.Install ground cables to both batteries.


NOTE: On vehicles equipped with EEC, when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.

7.Run engine and check for oil, fuel and coolant leaks.


WARNING: KEEP EYES AND HANDS AWAY FROM NOZZLE SPRAY. FUEL SPRAYING FROM THE NOZZLE UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.


8.If necessary, purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until bubble-free fuel flows from connection.
9.Install engine cover (E-250-350 only).

REMOVAL

1.Disconnect ground cables from both batteries.
2.Remove engine cover (Econoline only).
3.Remove air cleaner and install intake opening cover, Intake Manifold Cover T83T-9424-A.
4.Remove injection pump.





5.Remove bolts attaching injection pump drive gear cover to engine block, and remove cover.

NOTE: Do not remove drive gear yet.


6.Remove glow plugs with Glow Plug Socket D83T-6002-A or equivalent to facilitate turning engine over by hand.
7.Turn engine over by hand to TDC (top dead center), compression stroke of No.1 piston.


NOTE: To determine that No.1 piston is at TDC (compression stroke), position injection pump drive gear dowel at the four oclock position. The scribe line in vibration damper should be at TDC.

NOTE: To aid aligning the timing marks, the pump drive gear and the camshaft gear are marked with "Y" timing marks. The crankshaft and camshaft gears are marked with "0" (dot) alignment marks. With engine at TDC compression for No.1 cylinder, the "Y" marks should be aligned.







CAUTION: Do not remove injection pump gear without performing the following procedure.

8.Slide injection pump gear back (do not remove) to expose top of camshaft gear when looking down into the front cover. In addition to the "Y", the gear teeth adjacent to the "Y" on the camshaft gear are permanently dyed.
9.Remove injection pump drive gear.



INSTALLATION


1.Clean all gasket and sealing surfaces with a suitable solvent and dry thoroughly.

NOTE: To determine that No.1 piston is at TDC of compression stroke, position injection pump drive gear dowel at the four oclock position. The scribe line in vibration damper should be at TDC.

2.With drawn line on drive gear at six oclock position, install gear and align all drive gear timing marks.


CAUTION: Use extreme care to avoid disturbing injection pump drive gear, once it is in position.

3.Apply a 3.16mm (1/8 inch) bead of Silicone Rubber Sealant D6AZ-1 9562-BA (ESB-M4G92-A) or equivalent along bottom surface of injection pump drive gear cover.


NOTE: When applying Silicone Rubber Sealant D6AZ-1 9562-BA (ESB-M4G92-A) or equivalent always use the bead size specified and join the components within 15 minutes of application. After 15 minutes, sealant begins to set-up and sealing effectiveness may be reduced.

4.Install injection pump drive gear cover and tighten retaining bolts to 19 Nm (14 ft-lb). Apply Perfect Seal Sealing Compound B5A-1 9554-A (ESR-M18P2-A) or equivalent to bolt threads before assembly.

NOTE: With injection pump drive gear cover installed, the injection pump drive gear cannot "jump" timing.

5.Remove intake manifold cover and install air cleaner.
6.Install ground cables to both batteries.


NOTE: On vehicles equipped with EEC, when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.

7.Run engine and check for oil, fuel and coolant leaks.


WARNING: KEEP EYES AND HANDS AWAY FROM NOZZLE SPRAY. FUEL SPRAYING FROM THE NOZZLE UNDER HIGH PRESSURE CAN PENETRATE THE SKIN AND CAUSE INFECTION. MEDICAL ATTENTION SHOULD BE PROVIDED IMMEDIATELY IN THE EVENT OF SKIN PENETRATION.


8.If necessary, purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until bubble-free fuel flows from connection.
9.Install engine cover (E-250-350 only).




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