Speaking of this type of work...how do you get the 2 rails on the left side of 
the head that sit under the timing chain out?  I'm having problems getting mine 
out so I can replace the head....

Luther

On Thu, 14 Jun 2007 11:02:04 -0500, Jim Cathey <[EMAIL PROTECTED]> wrote:

> I paint-marked the cam sprocket and chain, the IP sprocket and chain,
> and the hub of the injection timer where the mark on the shaft of the
> IP is.  (That's a tough one, they're far apart.  I tried to line up
> the mark by eye.  If I don't wipe it off it should guarantee that I
> get the IP back in the same phase it came out in.)  Better safe than
> sorry!  I removed the chain tensioner and all five bolts holding in
> the injection pump.  (Three on the flange, the hub bolt, and one on
> the rear support bracket.)  I pulled off the fuel lines and vacuum
> hoses, then managed to yank the thing out of there.  It's a tight fit!
>
> With it out the big O-ring flange seal was exposed.  It was flattened,
> though still somewhat flexible and not cracked.  Not a smoking gun,
> but it could well be responsible: the area under the flange was very
> oily.  Of note is that the O-ring seal looks nothing like the (much
> smaller) seal I'd ordered from Rusty.  I think he sent me the internal
> shaft seal rather than the big flange seal.  One can result in oil
> leaks to the outside world, the other cannot.  I will have to get the
> right one.
>
> There is a timing adjustment screw on the back of the timing vault
> that mates with the IP's flange.  That would be handy when making fine
> adjustments.
>
> I went to the parts car and found that it does have the throttle
> damper on it.  I'm not sure if it's supposed to be a sluggish
> oil-filled thing, or more of an air-filled damper.  I'll have to find
> out, this one is definitely not full of oil.  It was not clear where
> the other end of the damper hooked on the parts car, there was nothing
> obvious left in place.  That could be fun.  Does anybody know the
> answers to these two questions?
>
> While I was down there I noted that the heat exchanger at the heater
> tap is sealed with a fat O-ring, and held in place with a spring clip.
> (The parts car's was undone.)  I also grabbed an alternator from out
> of the back of the '87 TD, we'll see if it's the right one and if it
> works.  I also checked that the parts car's AC compressor is not
> seized, so we'll be taking that at some point.
>
> The IP for the manual transmission car also has a vacuum control valve
> on the side of it, probably just for the EGR.  I'll probably be
> removing all this stuff anyway, it'll help reassembly and will
> cut clutter in the car.  (The EGR is already gone.)
>
> I'm going to call a few Bosch diesel service places in town to see
> what they'll charge to do a re-seal job on the pump.  If it's
> reasonable I may have that done.  (There are a number of places it can
> leak oil to the outside, and the delivery valve seals should probably
> be refreshed while they're there.)  I don't intend to have a full
> calibration done as I know that's a not insignificant expense.
>
> -- Jim
>
>
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-- 
Luther   KB5QHU    Alma, Ark
'87 300SDL (272,xxx mi) head case
'85 Ford F250 6.9 diesel (x58,xxx mi) BioBeast
'82 300CD (166 kmi)
'82 300D  (74 kmi) getting donor engine-sold
'85 300D (280,176) parts car sans engine

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