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OK, the dirty deed is done.
I'll step through replacing my injection pump..... This is just my experience,,,, others may have a better approach.
IMPORTANT - I would recommend not starting this process unless you have an electric fuel pump on the low pressure side of your engine; Used for bleeding purposes. ALSO, have a strong battery charger to keep your starting battery/s up during the bleeding process.
1. I found a rebuilt injection pump; much cheaper than having mine rebuilt. Mine was leaking from the shut off toggle switch.
2. This is a two man job so I would advise you find someone to help you. It would be nice if one of you has a small body frame that can fit AND work under the sink.
3. Remove the oil filter.
4. Remove the alternator.
5. Use some kind of cleaner to clean all around the injector pump mount.
6. Use something to score along where the pump is mounted to the timing chain cover. Try to mark EXACTLY where at least two of the mounting ears are. OR..... lock the pump gear in place. Along the bottom of the base (hard to see when mounted) there is a small hole in the mounting base, about 1/8''. Inset in that hole is a screw. Remove the screw and insert something like a 1/8" drill bit and tape it up so it won't drop out. This will lock the pump gear in place. This would be useful if you were going to have the pump rebuilt.
7. Disconnect all the fittings. We only removed one pair of the injector lines at both ends for easier access but I think it would have been better to remove all of the lines. It would have made getting the pump back in faster.
8. Once the lines are removed it's a simple thing to loosen the three nuts holding the pump in place. YOU WILL NEED a jointed rachet with an extension to remove the inside nut.
9. The pump gear stem is threaded. One place on it is wide which purpose is to act as a key. Therefore there is only one way to put the pump back in to the timing chain hole.
10. You'll need either a new gasket, make your own or use gasket in a tube before replacing the pump. This pump has no shims but I doubt you'll be able to remove the pump without tearing up the gasket.
11. Clean the mounting surface and with the new gasket, mount the pump, reinstall the oil filter, mount the alternator.
12. Align the pump with the score marks that you have made. If you locked the gears in place using a locking pin, simply remount the pump tighten the screws and remove the pin (don't forget to replace the screw in the little locking pin hole).
13. Reattach any/all injector lines.
14. BLEED THE LINES. Here's where an electric pump REALLY COMES IN HANDY. Start with the instructions in the Westerbeke engine manual. You'll see an additional step in those instructions when replacing the pump. You'll need to fill the pump up.... those instructions are there in the manual. We bled everything from the fuel filter to the injectors,,,, in that direction. It's trial and error after that. I opened up all of the injector ends many times, using the electric pump to bleed AND also firing up the engine to bleed. If your starter battery gets low. FORGET IT, leave the charger on the battery, go home, have a beer and get a good night's sleep. The next morning start bleeding only the injector heads again then try starting it up with a fully charged battery. Most likely it will begin to hit on one or more cylinders then "cheers" it'll start.
15. If you're lucky like me, it will run great provided it went back into the exact same place. IF not you'll need to adjust the pump.
This is done by loosening the 3 mounting screws and turning the pump slightly clockwise. The pump is not going to want to move by the way. It can be adjusted by locking vice grips on the opposite end of the pump so the pump could be torqued clockwise,,,, actually pretty easy. While one person does that have a second person screw in the TOP mounting screw (tight). This should keep it from moving while tightening the others. With luck, you'll won't need to adjust, even then, adjusting once should do the trick.
16. THE FINAL step.... check for leaks. I doubt you'll be able to get all the lines back without a slight leak somewhere.
17. Have a beer, take the wife out to dinner, throw a party, you're done !!
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