2-35.2. (6.5L) FUEL INJECTION PUMPS (DB2831-5485 OR DB2831-5079) CALIBRATION
This task covers:
Test Bench Requirements
Injection Pump Check (Prior to Service)
Injection Pump Information
Injection Pump Settings (Following Pump Repair)
Voltage source (variable)
Pressure gauge (0-160 psi, 1 psi increments)
Pressure gauge (0-30 psi)
Vacuum gauge (0-30 in. Hg)
Flowmeter with three-way valve
Temperature gauge (0°-250°F)
Zero-backlash coupling device
Calibrating nozzles and lines
Calibrating fluid (Appendix B, Item 4)
Sealing compound (Appendix B, Item 19)
a. Test Bench Requirements
The fuel injection pump requires a test bench capable of at least 2250 rpm shaft speed. The test bench
must be equipped with the following items:
(a) A zero-backlash coupling device.
(b) A digital tachometer.
A variable voltage source.
(d) Test gauges:
(1) 0-160 psi (0-1103 kPa) pressure gauge calibrated in 1 psi increments to measure transfer pump
pressure. This gauge should be located as close as possible to the pump, with an in-line shutoff
valve located at the pump.
(2) 0-30 psi (0-206.9 kPa) pressure gauge to measure housing pressure.
0-30 in. Hg (0-101.3 kPa) vacuum gauge to measure transfer pump lift. This gauge should be in
the supply line to the pump, with a shutoff valve between the gauge and the oil source.
(4) A flowmeter for measuring return oil should be used with a three-way valve to permit the
flowmeter to be in use only during the return oil check.
(5) 0-250°F (-17.8-121.1°C) temperature gauge, located at the pump inlet, to monitor inlet
General mechanics tool kit:
automotive (Appendix E, Item 1)
Roller-to-roller setting tool
(Appendix E, Item 45)
Linkage gap tool (Appendix E, Item 49)
Automatic advance indicator
(Appendix E, Item 50)
Vacuum valve block gauge
(Appendix E, Item 51)
Protractor (Appendix E, Item 52)
Air timing gauge (Appendix E, Item 53)
Holding fixture (Appendix E, Item 46)
Torx drive (Appendix E, Item 42)
The following calibration procedure applies to 6.5L turbocharged
fuel injection pumps. Refer to para. 2-34 for calibration of 1990
6.2L and above pumps and para. 2-33 for pre-1990 6.2L pumps.