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Pump tube
1 Refer to Fig. 11. Loosen and remove
housing tube (60).
2 Remove bronze bearing (56).
3 Using a flat, blunt tool, remove
O-ring (57), back up washer (58)
and O-ring (59).
4 Remove spiral retaining ring (61),
shovel plug (62) and retaining ring (63).
Assembly
Pump tube
1 Insert O-ring (59), back up washer (58),
O-ring (57) and bronze bearing (56)
into housing tube (60).
2 Apply medium strength threadlocker to
threads of housing tube (60) and torque
to 20–25 ft.lbf (27–33 Nm).
3 Insert retaining ring (61) into second
groove of housing tube (60).
4 Install shovel plug (62) into
housing tube (60).
5 Install spiral retaining ring (63).
Lower plunger
1 Insert check rod (22), spring (21)
and ball (23) into plunger portion of lower
bushing and plunger (24)
(† Fig. 10, page 12).
2 Apply medium strength threadlocker to
threads of plunger link rod (20) and
thread into plunger portion of lower
bushing and plunger (24).
3 Insert plunger portion of lower bushing
and plunger (24) into tool (T4), aligning
hole in plunger with hole in tool.
4 Insert pin (T5) provided in kit 276275
into alignment holes of tool (T4) and
plunger portion of lower bushing
and plunger (24). Torque to
110–125 in lbf (12–14 Nm).
Pump tube assembly
Upper plunger
1 Place outlet pin (8) into a vise.
2 Apply medium strength threadlocker to
threads of end of plunger portion of upper
bushing and plunger (10) and tighten
into outlet pin (8). Torque to
110–125 in lbf (12–14 Nm).
3 Install steel back up ring (17), O-ring (18)
and retainer clip (19) onto bushing
portion of upper bushing and plunger (10)
(† Fig. 9-E, page 12).
4 Clean threads of wrist pin anchor (13).
5 Install O-ring (14), back up washer (15)
and a new cup seal (16) in wrist
pin anchor (13).
6 Slide wrist pin anchor (13) onto upper
bushing and plunger (10).
7 Slide bushing portion onto upper bushing
and plunger (10).
8 Apply medium strength threadlocker to
threads of plunger portion of upper
bushing and plunger (10) and tighten to
plunger link rod (20).
Torque to 110–125 in.lbf (12–14 Nm).
13
Reciprocating tube
Fig. 11
1 Install cup seal (26) with slotted side first
56
and bushing portion of lower bushing and
plunger (24) with new O-ring (27)
into reciprocating tube (25).
2 Install ball cage (28)
57
into reciprocating tube (25).
58
3 Install ball (29) into ball cage (28).
4 Apply medium strength threadlocker to
59
threads of check seat (30). Thread check
60
seat (30) into reciprocating tube (25)
and tighten using a
5 Torque to 20–25 ft.lbf (27–33 Nm).
6 Place wrist pin anchor (13) with plunger
assembly in a vise († Fig. 9, page 12).
7 Slide reciprocating tube (25) onto
plunger assembly and tighten onto wrist
pin anchor (13) to
61
20–25 in lbf (27–34 Nm).
62
Crank rod/eccentric
63
assembly
1 Place crank rod (7) on the 2.5 in (62 mm)
steel pipe provided in tool kit (276275)
(† Fig. 8, page 11).
2 Install ball bearing assembly (6) into
crank rod (7).
3 Place crank eccentric (5) in ball bearing (6).
4 Place one end of inner retaining ring (4)
on top of crank eccentric (5).
5 Squeeze other end of the retaining ring (4)
toward center and slide retaining ring (4)
into place.
6 Place one end of outer retaining ring (3)
on top of inner retaining ring (4)
and slide into place.
7 Repeat steps 4-6 for opposite side.
8 Align holes of counter weights (2)
with threaded holes of crank eccentric (5)
and place on crank eccentric (5).
9 Insert flat head screws (1) the counter-
balance weight (2) and torque flat head
screws (1) to a torque of
100–110 in.lbf (11–12 Nm).
/
in (9 mm) hex key.
3
8
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