Before an injection pump comes off, confirm it’s really the problem, then photograph, mark and record everything about how it’s installed: the identification tag, timing marks, drive gear position, linkages, wiring and line routing. Clean the outside before opening anything, cap every port the moment it’s open, and keep shims, keys and small parts with the pump. Those steps make reinstallation straightforward and protect the pump from damage and dirt.
1. Confirm the diagnosis
Pulling a pump that wasn’t faulty wastes days. Before you start:
- Check fuel filters, the water separator and supply pressure
- Look for air in the fuel
- Confirm the shutoff solenoid works
- Check timing if the engine runs
- Read codes on electronic systems
See diesel injection pump failure symptoms for symptoms that point to the pump and those that don’t.
2. Photograph the pump tag
Clean the tag gently and photograph it straight-on and at an angle. Write the numbers down. The tag identifies the pump and its calibration. See injection pump identification.
3. Record the timing
- Marks. Photograph the timing marks on the pump flange and engine mounting surface. If there are no factory marks, scribe a line across both before loosening anything.
- Engine position. Follow the engine maker’s procedure for setting the engine to the specified position before removal, which may involve a timing pin or locking tool.
- Pump position. Some pumps have a locking provision or internal timing marks. Use them as specified.
4. Deal with the drive gear correctly
On some engines, the pump’s drive gear stays in the timing case and must not be allowed to move or come out of mesh. On others, the gear comes off with the pump. Know which applies before you start. When removing a gear from a tapered shaft, watch for the drive key: a small key dropped into the timing case is a real problem.
5. Document linkages, wiring and lines
- Photograph throttle linkages, stop cables and any external levers in their positions
- Label electrical connectors
- Label injection lines by cylinder, or photograph their routing
- Note fuel supply and return line positions
- On oil-lubricated pumps, note the oil supply and drain lines
6. Clean the exterior
Before opening anything, disconnect the batteries, and on common-rail engines follow the procedure for letting rail pressure bleed down. Clean around the pump and line fittings before loosening anything. Dirt around a fitting falls into the opening the moment it’s loosened.
7. Cap everything immediately
As each line and port comes off, cap it, on the pump and on the engine side. Use clean plastic caps, not tape directly on the opening and not rags, which shed lint. Keep injection lines capped at both ends.
8. Keep small parts with the pump
Shims, brackets, keys, washers and seals that came off with the pump go in a labeled bag with it. On some engines, pump timing is set with shims, and losing them makes reinstallation harder.
9. Don’t turn the engine afterward
Once the pump is off, avoid rotating the engine unless the procedure calls for it. If you must, record where it was and return it to the same position before reinstalling.
10. Pack and ship it properly
Drain the pump, cap every port, protect the drive end and controls, and pack it so it can’t move. Include a note with your contact information, the engine details and symptoms. See how to ship diesel injectors and pumps.
Why it matters
A correctly rebuilt pump installed with incorrect timing, the wrong shims or a misrouted linkage won’t run right. The documentation you collect before removal is what makes the return trip work.
Further technical reference: FedEx: guidance on shipping automotive parts · Bosch: Diesel Repair Network and supported component service. Use the exact engine/injector/pump service information for applicable procedures and limits.
Send DCT your pump
Before removing an injection pump, photograph its full identification plate, note the application and any engine-side test readings, and ask about the proper service path. If the pump is already removed, request DCT approval and receiving instructions before shipping or dropping it off at a confirmed Kansas location.
Before you ship: Request a mail-in component review to confirm part-number acceptance, packing rules, authorization, return shipping and timing.