Brass Tip FSS Plunger Install
Thank you for your purchase of our Brass Tip FSS Plunger!
The following will help walk you through the installation process of our plunger in an injection pump.
For this illustration we will be using a Bosch VE style Injection Pump.
(This injection pump has been removed from the engine for the ease of pictures for this install.)
YOU DO NOT NEED TO REMOVE YOUR PUMP!
Step I
Step III
Step II
First, we will need to locate the Fuel Shutoff Solenoid (FSS). This is located towards the back/top side of the injection pump.
Step II
Step III
Step II
Next, you will need to remove the wire(s) that will be attached to the top of your FSS. You can remove this nut with a 5/16” wrench.
Step III
Step III
Step III
Once you have the wire(s) off you will need to remove the FSS from the injection pump. For this you will need a 15/16” wrench.
Step IV
Step IV
Step III
Unthread the FSS from the housing.
Step V
Step IV
Step VI
These are the components that make up your factory Bosch FSS. There will be an O-ring on the bottom of the FSS, a spring, and the factory rubber tipped plunger.
Step VI
Step IV
Step VI
We will be reusing the spring and O-ring that came out of your FSS. DO NOT LOSE!
Step VII
Step VIII
Step VIII
Now, replace rubber tipped plunger with new Brass Tipped Plunger.
Step VIII
Step VIII
Step VIII
Reinstall the spring into your new Brass Tipped Plunger.
Step IX
Step VIII
Step IX
Next, clean out the bore and housing where the FSS is mounted. The O-ring will need a clean surface to seal properly. Take extra precaution to not drop any debris into your injection pump as this could cause severe damage to your fuel system.
Step X
Step XI
Step IX
We have found that it is best to first install your new plunger into the pump housing with the spring in the plunger. This helps alleviate the chance of you dropping the spring into the injection pump.
Step XI
Step XI
Step XI
Finally, reinstall the old FSS by threading it back on. Be sure that the O-ring is seated properly to the FSS prior to threading it into the housing. Then, reconnect the wires to the FSS.