AC 615 backhoe injector pump, aligning the marks

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   I have a 615 backhoe that I need to have the injector pump rebuilt. 
My issue is the timing marks. I have no access to the front of the motor other than 
complete removal of the radiator shroud meaning unbolting the bucket 
arms, removal of the radiator to get anywhere close to turning the 
engine over by hand. I've tried to get the marks to align by bumping the
 starter but it will not stop on TDC. I can feel the mark go by in the window so I know I'm close but that's the best I can do. If I could access the flywheel 
does anyone feel I have any chance prying that around to get the timing 
right? 

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GWhite Members Profile Send Private Message Find Members Posts Add to Buddy List Bronze Level Joined: 23 Aug 2021 Location: Michigan, USA Points: 4	Post Options Post Reply Quote GWhite Report Post Thanks(0) Quote Reply Topic: AC 615 backhoe injector pump, aligning the marks Posted: 23 Aug 2021 at 8:52pm
	I have a 615 backhoe that I need to have the injector pump rebuilt. My issue is the timing marks. I have no access to the front of the motor other than complete removal of the radiator shroud meaning unbolting the bucket arms, removal of the radiator to get anywhere close to turning the engine over by hand. I've tried to get the marks to align by bumping the starter but it will not stop on TDC. I can feel the mark go by in the window so I know I'm close but that's the best I can do. If I could access the flywheel does anyone feel I have any chance prying that around to get the timing right?

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DrAllis Members Profile Send Private Message Find Members Posts Add to Buddy List Orange Level Access Joined: 12 Sep 2009 Points: 20562	Post Options Post Reply Quote DrAllis Report Post Thanks(0) Quote Reply Posted: 24 Aug 2021 at 6:38am
	There is absolutely no need to align any timing marks. This is the 4-cylinder D-2200 engine, right ?? At the injection pumps mounting flange (where it bolts to the engine) make a good scribe mark on the pump flange and the front plate of the engine. This insures that you KNOW where the pump was positioned at before you remove it. Now, you can remove the pump by pulling it to the rear about 3 inches. What is left behind is the pumps drive shaft, which has a flat drive tang. On one side of this drive tang is a "DOT". Look inside the pump and the drive socket in the pump also has a "DOT". When you install the pump turn the pump over with a big screwdriver and align DOT to DOT and install the pump. Then, position the pump to align your scribe marks from earlier. You are 100% correct in time. I've never done a D-2200 engine, but I have done the newer turbocharged version called a 433-TI. On yours, I think I'd remove four exhaust manifold bolts and lift the exhaust manifold up and set it on the injectors return lines. Then, you can pull the inj pump rearward with the injector lines all attached to the pump. I'd bet you may have to remove the starter and the fuel filter base to gain enough room to work on that short little engine. Be very careful installing the pump so as not to roll over the drive shaft umbrella seals !!!!!! Edited by DrAllis - 24 Aug 2021 at 9:20am

GWhite Members Profile Send Private Message Find Members Posts Add to Buddy List Bronze Level Joined: 23 Aug 2021 Location: Michigan, USA Points: 4	Post Options Post Reply Quote GWhite Report Post Thanks(0) Quote Reply Posted: 24 Aug 2021 at 7:07pm
	Thank You!!! The rep at the rebuild shop told me much that same thing but I've had what I thought was good info turn into a pile of grief and frustration. I like the idea of taking the lines with the removal. That should make life a little easier. Oh, and yes it is a 2200 motor. Thanks Again for reaching out.

DrAllis Members Profile Send Private Message Find Members Posts Add to Buddy List Orange Level Access Joined: 12 Sep 2009 Points: 20562	Post Options Post Reply Quote DrAllis Report Post Thanks(0) Quote Reply Posted: 25 Aug 2021 at 6:32am
	My dot-to-dot assumes that when you take it apart, it actually is dot-to-dot. If it is 180 degrees off when you disassemble it, put it back together just as it was. If it isn't dot-to-dot, someone else has had the engine apart and assembled the driveshaft wrong. No big deal, but pay attention to how it comes apart.