Throttle Shaft Seal Replace

Fig. 23 Injection pump right side view. V8 engine:

Fig. 24 Installing tool J-29601 on injection pump. V8 engine:

V8 ENGINE

1. Disconnect both battery ground cables.
2. Remove air cleaner and air crossover and install air screens J-26996-2 or J-26996-10.
3. Disconnect injection pump fuel solenoid, housing pressure cold advance wires and fuel return pipe, Fig. 23.
4. Remove throttle rod, vacuum regulator valve, return spring and throttle cable bracket.
5. Place tool J-29601 over throttle shaft and pin, then position spring clip of tool over throttle shaft advance cam and tighten wing nut. Without loosening wing nut, pull tool off shaft. This will provide proper alignment during reassembly, Fig. 24.
6. Drive pin from throttle shaft and remove shaft advance cam and fiber washer. Remove any burrs from shaft which may have resulted from pin removal.
7. Clean injection pump cover, upper portion of pump, throttle shaft and guide stud area. Position several shop cloths in engine valley area to absorb fuel.
8. Remove injection pump cover and screws. Use care to avoid any foreign matter from entering pump when cover is removed. If any object or foreign matter enter pump, it must be removed before engine is started as injection pump damage or engine damage may occur.

Fig. 23 Injection pump right side view. V8 engine:

Fig. 25 Injection pump w/cover removed. V8 engine:

9. Note position of metering valve spring before removal as its position must be duplicated exactly during reassembly, Fig. 25.
10. Remove guide stud and washer, noting parts before removal.
11. Rotate min-max governor assembly up for clearance then remove it, Fig. 25. If idle governor spring becomes disengaged from throttle block, it must be reinstalled with tightly wound coils toward throttle block.
12. Remove throttle shaft assembly and inspect shaft for unusual wear or damage, replace if necessary. It may be necessary to loosen nuts at injection pump mounting flange and rotate pump slightly to allow throttle shaft to clear intake manifold.
13. Inspect throttle shaft bushings in pump housing for damage or unusual wear. If replacement of bushings is necessary, it must be performed by a qualified repair facility.
14. Remove throttle shaft seals. Do not cut seals to remove, as any nicks in the seal seat will cause leakage.
15. Install new shaft seals, lubricated with chassis grease. Use care to avoid cutting seals on sharp edges of shaft.
16. Carefully slide throttle shaft into pump to point where min-max governor assembly will slide back onto throttle shaft, Fig. 25.
17. Rotate min-max governor assembly downward, then hold in position and slide throttle shaft and governor into position.
18. Install new fiber washer, throttle shaft advance cam (do not tighten screw at this time) and a new throttle shaft drive pin, Fig. 23.
19. Align throttle shaft advance cam so tool J-20601 can be installed over throttle shaft, pins in slots and spring clip over advance cam.
20. Insert a .005 inch feeler gauge between cam and fiber washer, then tighten cam screw and remove tool J-29601.
21. Install guide stud with new washer, assuring that upper extension of metering valve spring slides on top of guide stud. Torque guide studs to 85 inch lbs. Over torquing may strip the aluminum threads in the housing.

Fig. 26 Installing injection pump cover. V8 engine:

22. Hold throttle in idle position and install new pump cover seal. Making sure that screws are not in cover, position cover about 1/4 inch forward toward shaft end and above 1/8 inch above pump, Fig. 26. Move cover rearward and downward into position, using care to avoid cutting seal, then reinstall cover screws. Each screw must have a flat washer and internal lock washer, with flat washer against pump cover. Torque screws to 37 inch lbs. and install vacuum regulator.
23. Reconnect both battery ground cables, then turn ignition switch to run position and touch pink solenoid wire to solenoid. A clicking noise should be heard as the wire is connected and disconnected. If not, the linkage may be jammed in the wide open position and the engine must not be started. Proceed to step 24. If clicking is heard, connect pump solenoid and housing pressure cold advance wires and proceed to step 25.
24. Remove cover, then ground solenoid lead (opposite hot lead) and connect pink wire. With ignition switch in run position, the solenoid in the cover should move the linkage. If not, the solenoid must be replaced. Minimum voltage across solenoid terminals must be 12 volts. Reinstall cover and repeat step 23.
25. Install throttle cable bracket, throttle rod, throttle cable and return springs. Make sure timing marks on pump and adapter are aligned and make sure nuts retaining pump are tight. Install fuel return pipe.
26. Start engine and check for fuel leaks. Rough idle may be due to air in the pump. Allow sufficient time for air to purge by allowing engine to idle. It may be necessary to turn engine off to allow air bubbles to rise to top of pump where they will be purged.
27. Adjust Transmission Vacuum Valve as described further on, then remove intake manifold screens and install air crossover and air cleaner.