Fuel Pump Alignment

[KrustyKruiser]

Hi Folks:



My son's 92 caught a KDP cold and we are in the middle of a (very expensive) fix. The gear case was pretty much destroyed; luckily, the gears were not harmed. Anyhoo, our problem is that we did not realize there were no alignment markings on the fuel pump gear when we dis-assembled, and now are scratching our heads trying to figure out how to re-install it. I guess we saw the markings on the cam gear and crank and figured that there must be corresponding markings on the fuel pump gear, but alas, that is not the case. Any procedure/recommendations for installing the fuel pump?



Many thanks,



Andy

 

[tugboatphil]

Andy,



There are a lot smarter folks than me that will answer your problem. First of all, I'm sorry that you're here because of such a big problem, but I would like to welcome you aboard! This forum has been such a help to me that I don't know how to put a price tag on it. The membership has paid for itself many times over.



Good luck with the repairs!!

 

[KrustyKruiser]

Thanks Phil - I appreciate the warm welcome I just spent some quality time using the search function, and I think I have the answer - maybe someone can verify this, but it seems the one simply aligns the pump gear "letter" with the cam gear marks. As we have a Bosch VE pump it looks like we align using the letter E that is stamped on the fuel pump gear. Any thoughts??



I have been lurking around the TDR for some time, and am on the brink of buying a CTD for myself. Looking at a 2001 Ext cab, 4x4 short bed with auto transmission.



Andy

 

[guava]

I've had several different explanations given to me and none handle matching up the gears after having it all apart.



But... . if memory serves me. . Putting the number one cylinder in TDC lines up all the gears in such a way so that the injector pump shaft has the 'key' in the down position.



Of course the sage advice passed around is to install the pump with the key facing up so as not to drop it into the case and repeat your problem.



Hopefully, someone else can verify this info before you get to far into it.



Good luck and welcome.

 

[DValentine]

Andy,



There should be two dots on the fuel pump gear. These will match a single dot on the cam gear. The other side of the cam gear has two dots that correspond with the crank gear... . having one dot I had mine apart a few months back but can't remember what it looked like. Your engine is TDC no. 1 cylinder? Is the front cover still off? Are you looking at the correct side of the fuel pump gear? ---just brain storming.



Dave

 

[KrustyKruiser]

Dave,



Thanks for your response; we checked both sides of the fuel pump gear and could not see any stamped dot similar to those found on the cam and crank gears. Yes, the front cover is off. I am pretty sure that the letter alignment is the way to go now.



BTW, as the KDP was mangled in the gears we did not install it. I am now having reservations as I understand that the pin is necessary for gear case allignment and could affect the fuel pump gear. Looks like I will have to pull it all apart to install a new KDP (with retainer, this time).



Andy

 

[Greenleaf]

Unless I missed something in the reading. the pin will install from the front, unless you have the case with the built up boss on the outboard end of the hole??????



The letter alignment is the way to go. I don't have the book in front of me at this time. Letter "E" seems to stick in my mind... ... ... ... ...



GL

 

[tugboatphil]

and am on the brink of buying a CTD for myself. Looking at a 2001 Ext cab, 4x4 short bed with auto transmission.

Andy,



You're on the right track here..... but you need to get a 1st Gen. If not, you'll be just another "new" truck owner. Besides, we could use a screen name like KrustyKruiser in this forum!! Anyone second this motion??

 

[Ncostello]

The pin will install by just removing the sheet metal cover. No need to pull the entire gear case apart.



The only way you would not be able to install the pin is if the new or new/used case you used is an improved case designed for the ISB engine (although not always used on all 98-99 and even some 2000 ISB's).



Are all improved cases just for ISB engines with the VP44 pump our does Cummins sell replacement improved cases for all model years/injection pump types?



The improved case has a lip edge around the opening of the Dowel Pin bore. This lip edge prevents it from falling out.



There were two types of original cases. One had a flat area around the KDP bore which would allow a tab fix using the nearest bolt. The other used a bossed area (made the bore deeper) around the KDP bore which made the tab harder if not very unlikely.



The third design included the lip edge in the bossed bore area. If your new case is the improved design then you will have to take the case back off gears and all.



Unless you mill or shave the lip edge of the bore while its on the truck. Then you can just do a KDP fix and save alot of work.

 

[KrustyKruiser]

Andy,



You're on the right track here..... but you need to get a 1st Gen. If not, you'll be just another "new" truck owner. Besides, we could use a screen name like KrustyKruiser in this forum!! Anyone second this motion??

Thanks Phil! I think having one Gen 1 in the family counts; it makes sense to get a Gen 2 as it will keep the wife happy! My screen name derives from my love of old Land Cruisers, and the fact that I 'aint no spring chicken



Andy