Folks,

Let me start things off by saying I messed up. I decided today was gonna be the day I fixed the injection pump drive gear housing oil leak. I got to the step where you're supposed to remove the injection pump from the adapter housing when my genius idiot self thought it would be a good idea to not listen to the very specific service manual I had and instead remove the entire adapter housing with the pump and gear still installed. I told myself "it'll be fine, just make sure the gear doesn't spin any".

The gear spun.

So now that I've taught myself a lesson on following the service manual...I'm stuck with having to re-time this sucker. The service manual says bar it over to TDC then line up the Y marks on the camshaft and IP drive gears. I've already found the Y on the injection pump drive gear but I know there's a 1 in a million chance I'm gonna be able to see the camshaft drive gear mark without pulling off the front cover (and pretty much the rest of the front of the engine). So, here's what I need help with:

1. Is there a way to align the timing marks without removing the front cover of the engine? I don't own a borescope but I'm considering that as a possibility.
2. My service manual says to bar it over until cylinder 1 is at TDC but it also calls for removing the right valve cover to observe the cylinder valve lever. Is this necessary? I'd like to avoid having to replace a valve cover gasket....but at the same time I got myself into this mess trying to cut corners so if that's the proper way of doing things I'll do it that way.

Any other advice y'all have on this procedure would be greatly appreciated once you're done laughing at my stupidity :P

Thanks!

 

Search thru the forum, it has been discussed before! I don't remember all the details, or who did the same mistake you did, but it can be fixed without tearing the front cover off.

Borescope might work well, as that can get you down in there and see whats going on.
I believe it has been done with a small mirror on a stick and a bright light. Its possible the person used a shiny butter knife with a bright light to check.

Its ok, you are not the first to do this, and you won't be the last. I need to do the same thing as I'm getting tired of my truck marking its territory everywhere, but I don't feel like going to the work of pulling the injector lines, pulling the pump, putting it all back, and diddling with the timing again, although I do have a decent timing unit, its still a pain in the butt.

 

I think I remember somebody taking a small thin mirror and having someone else turn the engine by hand to find the mark. It’s very tedious but it has been successfully done without pulling the front cover.

I am certainly not laughing because that’s a major PIA lol but like tecgod said, your not the first and you won’t be the last.

I’m not sure if my housing leaks or if it’s just the plate with the two bolts, but I too have an oil leak there. My truck has a lot of issues, and that oil leak ain’t one haha

 

Well folks,

Tried the borescope. No dice. Given how tight the gear is against the front cover I don't see how even with a mirror I'd be able to see the timing mark so it looks like the front cover is going to have to come off.

Lesson learned I guess.

 

Would you be able to feel the mark with a small pick? I’m just grasping at straws before you have to pull the cover

 

 

I don’t know if those pics help, but would it be easier to pull cyl 1 valve cover and get it to TDC then look and feel for a mark?