231S2 fuel injection pump

[Rayleach2]

How to remove injection pump to replace front seal, Lucas Delphi DP200 8922A24IT

 

[MFEngineer]

DP200 has not got a keyed shaft - DO NOT REMOVE THE FRONT COUPLING, you will lose the timing. You have to time the engine and lock the pump before removing. There is shoulder bolt with a double holed washer near the front on the side of the pump, slacken the bolt, move the washer to the big hole and tighten it so that it tightens onto the shaft inside the pump and the washer is loose. The pump is now locked for TDC. Then remove the three bolts round the pump gear (you may need to remove the water pump depending on which engine it is fitted to. The pump has to be dynamically timed on a test bench with and encoder, best to send it to a Delphi agent, or buy a new pump. If the front shaft seal has gone hard so will the rest of the seals.

 

[Dieseltech]

Turn the engine until the U shaped notch on the pump FLANGE EDGE is at the six O clock position and insert a 5/16 drill bit into the location hole into the pump FRONT, this will locate the hub NOTCH for correct timing. Pump can now be removed/replaced, but DO NOT turn engine while pump is off. After pump is off it MUST be handled by qualified personnel to remove/replace the hub and seals as the hub IS NOT keyed on the tapered drive shaft.