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Hi, I have replaced lip seal on the shaft on my brother's 454 with German D179 3 cyl Diesel twice in the last 10 years. I believe reason for failure is the new low sulphur Diesel fuel dosen't have the same lubrication as the old Diesel fuel that these Bosch injection pumps were designed for... so add a little Diesel fuel conditioner or engine oil to Diesel fuel every time you refill the tractor. Enough of a rant and onto doing the repair. Procedure:
1)Shut off fuel from supply tank with screw cock at bottom of tank on both sides. 2)Clean all around injection pump and blow with compresed air if possible. 3)Remove throttle control rod and shut off cable. 4)The injection pump is mounted to the timing gear cover by 3 studs with nuts and lock washers. VERY IMPORTANT:
Before loosening these nuts, use a scribe and carefully mark the exact location of the injection pump onto the timing gear cover. 5)Loosen and remove fuel supply line and injector feed lines. Cover exposed ends of fittings and lines with a clean cloth to prevent dirt from entering the openning. 6)There is an inspection hole cover on the front side of the timing gear cover held on by 4 nuts and washers. Remove this cover to expose the timing gear. 7)DO NOT TOUCH the small bolts in the timing gear as this is the course timing adjustment.
Using a socket wrench loosen the big nut on the shaft in the center of the timing gear. This is the drive shaft to the injection pump. Do not remove the nut completely. Hint you may have to stick a screw driver thru the hole in the timing gear to prevent it from turning when you are loosening the shaft nut. 8)Remove the 3 nuts and washers that fasten the injection pump to the timing cover. 9)IH has a special gear puller to push the drive shaft out of the timing gear. This is not the approved method but I do this:
Screw the big nut off until it is flush with the end of the shaft and then use a palstic hammer to hit the end of shaft driving it out of the timing gear. Since it is a taperred shaft once it is loose it will come right out. Becareful not to damage the threads on the shaft. 10)Once the shaft is loose in the timing gear, hold the injector pump firmly in one hand and remove the big nut from the drive shaft. Now work the injector pump up and down a little while pulling towards the rear of the tractor and it should come out of the timing gear. Becareful not to loose the half moon key in the drive shaft. Caution: DO NOT ROTATE ENGINE WHILE PUMP IS REMOVED. 11)Remove half moon key from drive shaft and use a seal extrator tool to remove lip seal. Becareful not to scratch drive shaft. 12)Check the drive shaft for a groove been worn were the seal is installed. If there is to much of a groove in the drive shaft the new seal may not fix the problem. 13)Clean area around drive shaft and lip seal housing. Apply plenty of seal lubricant to shaft.
Re install lip seal being careful to keep it aligned properly. I usually start it in the housing with my fingers and then use a deep socket that is the same size as the lip seal to drive it into the housing. Again make sure it is properly aligned as it is being installed. Apply more seal lubricant around the lip seal. 14)Re install the half moon key in drive shaft and make sure the key is properly aligned with the taper of the drive shaft. 15)Replace injection pump to timing cover gasket then re install the injection pump back onto its mounting studs making ABSOLUTELY SURE the injection pump shaft key aligns perfectly with the keywave in the timing gear. 16)Put the big nut back on the drive shaft and slowly tighten making sure shaft and keyway and pump is aligned on 3 mounting studs. Tighten nut on drive shaft to 48 ft-lbs. 17)Start the 3 nuts and washers on the 3 mounting studs but do not tighten at this time. The one in the rear is a bit of a challenge if you have large hands. 18)Reconnect the fuel line and injector lines. You may have to turn the injection pump slightly to get these connectors to align. If they don't start with your fingers they are not aligned properly. Do not force them with a wrench. ONLY TIGHTEN FINGER TIGHT at this time. 19)Now reposition injection pump to the scribe lines that you made on timing cover plate and tighten the 3 mounting nuts. 20)Now tighten fuel line. 21)Replace gasket on inspection hole cover and re install cover. 22)Re connect throttle control lever and shut off cable. Check shut off cable for proper operation. 23)Turn on fuel cocks and bleed fuel system and injector pump. 24)With tractor in neutral and parking brake set and the START/RUN/STOP lever in the START position crank the engine with the starter until fuel shoots out around the finger tight injector line nuts. Now tighten injector line nuts and engine should start. You may have to retighten the injector line nuts after the tractor warms up to stop any leaks. If injector pump was re installed to the scribe lines that you made on the timing gear cover there should be not requirement to adjust the injector pump timing. Now disclaimer: I don't take any responsiblity for this procedure,
you may use at your own risk. Hope everything works good for you it is a lot of work for a $5.00 seal. Good luck
JB2
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