Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
1981 Chevrolet Chevette Base, 4D Hatchback, 1.8L Eng VIN D, Automatic TransFACTORY OEM SERVICE PROCEDURE
Injection Pump Housing Fuel Pressure
- Engine must be at normal operating temperature. Remove air crossover assembly and install screen covers over openings in intake manifold.
- Remove pressure tap plug from injector pump.
- Place seal from pressure tap plug onto pressure tap adapter J-28382 and screw adapter into pump housing in place of plug. Screw pressure tap adapter J-28526 into pressure tap adapter J-28382.
- Connect a low pressure gauge to adapter. Install magnetic pickup tachometer. Start engine and run with transmission selector in "P". Pressure should be 8-12 psi, with no more than 2 psi fluctuation.
- If pressure is zero, remove connector from housing pressure cold advance terminal. If pressure is still zero, remove injection pump cover and inspect solenoid operation. Free up solenoid if binding.
- If pressure rose when solenoid lead was disconnected, check operation of temperature switch on rear head bolt. Switch should open above 125°F, then close when temperature drops to 95°F.
- If pressure is still incorrect, replace or clean fuel return line connector assembly and return line.
- Recheck pressure. If pressure is still not correct, remove injection pump for repair. Pump is not serviceable and must be exchanged for another unit. See INJECTION PUMP REMOVAL .
- Remove tachometer, pressure gauge and adapter. Install a NEW pressure tap plug seal on plug. Install tap plug into pump.
- Remove screened covers from manifold. Install air crossover assembly.
Factory Service Tools
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
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