Injection Pump Lever Won't Turn On with Key
 

I just replaced the head on the '86 SDL. It took two evenings to do this.

Now I can't start the engine without flipping the shutoff lever up (in the ON position). When I turn the key on, it does not move out of off.

I'm trying to remember how it operated before the rebuild. When the key is turned off, vacuum is applied to the diaphragm and the lever loves to the off position and when the key is turned on the lever moves to the on position?

I haven' had a great deal of time to fiddle with this and I'll look at it more closely when I get home, but I thought I'd get some ideas first.

When you disconnect the vacuum hose to the shutoff diaphragm does the lever go up to the normal operating position? If it stays down, in the off position, that indicates a problem with the injector pump (or vacuum maybe even the shutoff diaphragm). On the other hand, if it rises, as it should, the problem is vacuum related.

Yes. When you turn the key to off, the key switch routes vacuum from the brake booster line check valve to the shutoff actuator. When you turn the key to run, the key switch blocks the vacuum supply line and vents the shutoff actuator line. They're two separate actions performed simultaneously within the same switch.

Sixto
87 300D

Did it get bent and is somehow binding? As mentioned above, remove the vacuum line to see if it returns to the up position without vacuum.

Yes, when I pull the line, the lever goes to the on position. There must still be vacuum in the line.

Either the switch is defective or I put the wrong line on the IP.

I didn't disconnect too many lines, I can't imagine that I put the wrong one on, but I could have. The engine does turn off, but not crisply. It takes a couple of seconds to turn off.

Which line goes to the IP? Anyone have a diagram?

I can look at my car tonight.

-J

If the lines are reversed on the ignition switch assembly, seems that it will turn off the vacuum source, but not vent it.

If you have original lines, brown is supply vacuum to the key switch, brown with red stripe is signal vacuum from the key switch to the shutoff actuator.

Sixto
87 300D

I think it is brown with one red stripe going to the IP shutoff. I'm going to have to put a meter on the line an see what it does during on and off.

This morning the lever was pulled to the off position. Apparently there was still vacuum in the system to do this.

If you were to pull the vacuum line and push down on the lever, would the lever stay down? And to get it in the up position, when pulling up on the lever, do you have to get past an indent that you have to "pop" it out of?

I'm wrong. It's actually brown with a blue stripe.