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I looked and looked and couldn't find a way to line them up exactly
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Ok, it's really quite simple.
Sounds a bit complicated but it's not.
On the injection pump gear, you need to find the "y" mark. Turn it so the "y" mark is down at the bottom. On either side of that mark count upwards 19 teeth. Mark a line across the front of the gear between the 19th tooth on each side up from the "y" mark. Next, mark a line up from the "y" mark through the center of the gear at exactly 90Deg to the first line.
Now, you have to turn the engine to TDC. (#1 piston at top of it's travel at compression stroke-must not be on exhaust stroke) Make sure the line on the balancer aims exactly at "0" on the timing plate(found down under the alternator.) If you are on exhaust rather than compression stroke, the timing will
be out by 180 Degrees. The engine may
run, but will be very difficult to start, smoke whitish like you wouldn't believe, and not have any discernable power.
Once you have all this done(sounds more complicated than it is.) the "y" mark on the camshaft gear will be at the top. You then drop the injection pump gear into place so that the "y" mark is on the bottom, and the vertical line is in the center of the detent in the front plate, and the horizontal line between the 2 teeth is exactly parallel to the top of the engine.
It should look like this:
If you do this, it will be perfectly lined up. If you're out by even one tooth, nothing will line up. You'll see. Put the pump cover back on being careful not to lift/move the gear. Install the pump, and you're good to go.
It doesn't require dental mirrors or flashlights or any kind of pain. and only takes about 20 minutes or so.
If you have any problems, PM me, and I can walk you through it. I also have a complete engine apart in my shop right now if you need any more pics.
Good luck with it.
'86, 7.0L, 4x4, 4sp, 3.54 gears,Dana 50 monobeam, Ranger overdrive, Banks/Hypermax-Hybrid 3 1/2 exhaust, Ram air, Propane,CD Glowplugs, Air bags, everything rebuilt, 300,000+,still tickin',
My Website here,
Now: '93 F350TurboCrewcab 4x4 E4OD with dead 7.3, soon to be replaced with new 7.0LTurbo(bored 6.9)
Wife's car: '86 mercedes 300 T.D.