Injection Pump Cover Seal Replacement

Tool Required: J 29664 Manifold Cover Set.

REMOVE OR DISCONNECT:
1. Negative battery cables.
2. Air cleaner and intake manifold. Install J 29664 in the cylinder heads.
3. Injection pump fuel solenoid wire.
4. Housing pressure cold advance wire.
5. Fuel return line.
6. Top attaching bolt and loosen the lower attaching bolt on the fast idle solenoid. Move the solenoid aside.
7. Injection pump cover screws.

CLEAN:
- Injection pump cover.
- Upper portion of the pump.
- The guide stud area.
- Place several rags in the engine valley to catch fuel.

CAUTION: Extreme care must be used to keep foreign material out of the pump when the cover is off. If any objects are dropped into the pump, they must be removed before the engine is started or injection pump and engine damage could occur.

8. Injection pump cover.
9. Pump cover seal from the pump cover.
10. Pump cover seal from the pump.

INSTALL OR CONNECT:
1. New pump cover seal in the pump cover.

CAUTION: When installing the pump cover it is possible to locate the shutdown solenoid pivot arm on the wrong side of the linkage hook tab. This condition would cause the engine to go to "FULL RUN" operation, causing the engine to accelerate to very high speeds. This could cause damage to the vehicle.

Shutdown Solenoid Retaining Tool:

2. The pump cover using Stanadyne tool no. 26528 or equivalent
Note:
- If this tool is not available, a different procedure must be used. Refer to step #3.
- The screws should not be in the pump cover.
- Position the cover on the pump.
- Rotate the tool and slide it from beneath the cover with the cover in position.

Installing The Injection Pump Cover:

3. The pump cover without tool.
- Use this procedure if Stanadyne tool is not available.
- The screws should not be in the pump cover.
- Position the cover about 6 mm (1/4 inch) forward (toward the shaft end) and about 3 mm (1/8 inch) above the pump.
- Move the cover rearward and downward into position, being careful not to cut the seal. Hold throttle in the idle position.

4. The cover screws.
- Be careful not to drop or lose the flat washer and spring washer on each screw.
- The flat washer must be against the pump cover.
- Tighten screws to 4 Nm (35 in lbs).

5. Negative battery cables.

INSPECT:
Turn the ignition switch to the run position and touch the pink wire to the solenoid connector. a clicking noise should be heard as the wire is connected and disconnected. If this clicking is not heard, the linkage may be jammed in the wide open throttle position and the engine MUST NOT BE STARTED. If clicking is not heard, remove the cover and ground the solenoid lead (opposite the hot lead) and connect the pink wire. With the ignition switch in the run position, the solenoid in the cover should move linkage. If not, the solenoid must be replaced. Minimum boltage across the terminals must be 12.0 volts. Install the cover and repeat the inspection.

6. Fuel return line, throttle cable, and the return springs.
7. Fast idle solenoid.
8. Housing pressure cold advance wire.
9. Injection pump fuel solenoid wire.
- Start the engine and check for leaks.
- Idle roughness may be observed due to air in the pump. Engine idling will allow the air to purge. It may be necessary to shut the engine down for several minutes to allow air bubbles to rise to the top of the pump.

10. Intake manifold and air cleaner.
- Remove J 29664.