Thermo King T-500R Maintenance Manual page 162

NOTE: The injection pump gear assembly is made of two pieces, the flange and the gear. Do not
loosen or remove the four bolts that fasten the gear to the flange because that changes the timing.
5. Use a suitable puller to loosen the injection pump gear from the injection pump shaft.
6. Remove the injection pump gear mounting nut and lock washer. Use a shop rag to prevent the lock washer or nut from falling
into the gear case.
7. Remove the injection pump from the gear case, but leave the injection pump gear in the gear case. This keeps the teeth on the
injection pump gear aligned properly with the teeth on the idler gear. If you remove the injection pump gear from the gear
case you will have to remove the gear case cover to realign the timing marks on the injection pump gear and the idler gear.
Injection Pump Installation
1. Place a new O-ring on the injection pump and lubricate it with engine oil.
2. Place the injection pump in the gear case. Rotate the injection pump shaft to mate the key in the shaft with the keyway in the
injection pump gear. Take care to make sure the key mates with the keyway.
3. Secure the injection pump to gear case with previously removed hardware. Make sure to align the index marks on the injection
pump and the gear case like they were in step 1 of Injection Pump Removal.
NOTE: If a different injection pump is being installed, see "Injection Pump Timing" on to set the
timing.
4. Secure the injection pump gear to the injection pump shaft with the lock washer and mounting nut. Use a shop rag, as before,
to prevent the lock washer or nut from falling into the gear case. Torque the nut to 43.5 to 50.9 fT-lb (59.0 to 69.0 N•m).
5. Install the injection pump timing cover on the gear case cover, and reinstall all components removed previously to facilitate
the injection pump removal.
1. Injection Pump
2. Gear Case
3. Gear Case Cover
4. Injection Pump Timing Cover
Figure 1: Injection Pump Removal and Installation (3 cylinder engine shown as example here)
1
8
7
5.
6.
7.
8.
Engine Maintenance
2
6
5
Injection Pump Gear Mounting Nut
Lock Washer
Injection Pump Gear
O-Ring
3
4
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