You do not have to remove the timing cover to pull the injection pump.
After you remove the raw-water pump drive tang from the end of the injection pump shaft, you can hold the timing gear in place with one hand while you slide the pump aft with the other to pull the pump.
My woodruff key was oriented "up" and came out with the pump without a hitch. If you find yours in another position, turn the engine as required so that it sits upward before pulling your pump.
I used a zip ties to hold the timing gear and friction washer in place in the timing case while I had the pump out. I think the gear would've stayed in place without doing this, but it gave me peace of mind while the pump was away for servicing.
My timing marks were obscured by a motor mount and I suspect yours are too. Before I removed my pump, I made my own timing marks (adjacent punch marks on pump flange and timing cover) to re-align the pump when I re-installed it. I've now acquired an endoscope (bore scope) and can see the original marks with this really handy device so that might be another option for you.
I installed the injection pump gasket
to the pump with gasket adhesive
on the injection pump and let it fully cure before re-installing the pump. I did not use gasket sealer of any kind on the timing case side, just a little engine oil
. This allowed the the pump to easily rotate for timing once it was mounted. If you use Permatex or gasket adhesive
on both sides I think it would make this a sticky job trying to finely move the pump to align the marks and possibly damage the gasket. YMMV
My boat is fairly small. I did this job mostly laying on my belly on a 2 x 12 I cut to fit over my engine compartment when the hatch
is open. I removed the intake manifold and air box, fuel lift
pump, secondary fuel filter mount and the dipstick to get clear access to the pump.
I used Diesel
Injection Specialists in Portland
OR on the recommendation of my local machinist. They were outstanding in communication, service
and got the job done quickly and for a fair price
. I highly recommend them if shipping
from your locale is feasible.
BTW I have a second pump that the shop checked for me and okayed if you're interested. I got it from the classifieds here on the CF when I purchased a bunch of W52 parts
from a member
who had re-powered. Let me know if you're interested.
It's now been about three years since this job became another one for the books
. The most difficult thing I can remember was getting some of the clamps and brackets for the Morse cables
re-installed because of access and visibility. Overall it went smoothly. Good luck!