ARMY TM 9-2815-256-24
AIR FORCE TO 38G1-96-2
MARINE CORPS TM 2815-24/5
Remove pump (22) from mounting studs (25).
Cover all openings in pump and place pump in a clean area.
Work area must be clean and dirt free prior to disassembly of the fuel injection pump.
Prior to disassembly, ensure a clean pan with diesel fuel or calibrating oil is available. Also, ensure
a clean pan is available to store disassembled parts.
Do not discard seals, gaskets, insulator washers, and preformed packing during disassembly.
Seals, gaskets, and preformed packing are to be removed and discarded during assembly. Do not
discard retaining ring.
Cover inlet and outlet ports.
Eye protection must be worn prior to performing any cleaning. Personal injury or blindness can
occur if solvents get in eyes.
Clean external grease and dirt with diesel fuel. Blow dry with compressed air.
Using a flat-blade screwdriver, remove pilot tube seal (1, FIGURE 3-73) from mounting flange end of pump.
Always use holding fixture to mount injector pump and prevent injector pump from being damaged
during disassembly. NEVER damp pump in a vise. Damage to pump may occur. Fabricate
holding fixture in accordance with FIGURE D-1, Appendix D.
Mount injection pump in holding fixture.
If necessary, remove connector (1, FIGURE 3-64) and preformed packing (2) from cover.
Remove two screws (3), lockwashers (4), washers (5), cap (91), screw (92), and sleeve (93) securing governor
control cover (6). Remove cover (6) with solenoid (16) and gasket (7).
Remove two self-locking nuts (8), terminal (89), insulator (90), and diode from solenoid studs.
If equipped and damaged, remove terminal strap (9), and washer (11) and lockwasher (10).
Remove two nuts (12), one lockwasher (13), one washer (14), and two insulator washers (15) securing solenoid
(16) to cover (6); remove solenoid.
Remove two insulating tubes (85 and 86).
Rotate shut-off lever (27) to wide open throttle (WOT) position.
Never reuse shut-off lever (17). Always use a new one.