Injection Pump Reinstall Problem on 6.5 Turbo

[GMVguy]

Installing a new (rebuilt) Stanadyne Injection Pump and running into a problem so I stopped.

After lining it up with the timing mark I made before removal, as well as ensuring the pin is in the slot inside the motor, I snugged up the nuts on the front of the IP.

Then I installed the first bolt in the front (see pic below). I snugged it up finger tight and went to rotate the motor to access the next bolt hole using the nut on the alternator, as I did for removal. The motor wouldn’t budge. During removal it rotated pretty easily, so I didn’t want to force it and went to inspecting things.

In the picture below, it seems the driveshaft from the front of the IP is not exactly lined up with the black part. How do you know if the IP driveshaft is lined up? And would that cause the engine to not manually turn over?

 

[Gastrap]

Bolt looks dirty, Is that possibly a bolt from and external location? maybe too long and binding? I think there are usually captive washers on the gear bolts, not flange heads. Those thrust areas on the cover aren't always dead center.

 

[NDT]

Were you able to rotate the IP shaft prior to installation?

 

[GMVguy]

Bolt looks dirty, Is that possibly a bolt from and external location? maybe too long and binding? I think there are usually captive washers on the gear bolts, not flange heads. Those thrust areas on the cover aren't always dead center.

No, that’s one of the three original bolts. Seems to seat fully and not be causing any binding. I would try to turn the motor without the bold, but don’t want to mess up the timing.

Thanks for the tip on the area the plunger hits not always being dead center. That’s what was concerning me, as if it should line up and fit into the cover somehow.

Not sure what else could be binding the motor from turning to the next bolt.

 

[GMVguy]

Were you able to rotate the IP shaft prior to installation?

Yes, the IP shaft spins freely when tested, and plunges in and out with the spring no problem.

 

[NDT]

This is kinda confusing, the IP can really only go in one way, the goof on this install is to drop a screw down into the guts.

 

[Retiredwarhorses]

STOP
if you tighten these bolts without being completely seated and flush on the timing gear, you will break the pump shaft, its a milled surface and it’s tight, remove all bolts, push on the timing gear with your fingers and shake the pump while pushing the pump, the two surfaces will be flush When done correctly.

 

[GMVguy]

@Retiredwarhorses saves the day again. Thanks all!