101049-5010 ZEXEL 9 410 610 303 BOSCH FUEL-INJECTION PUMP 9410610303 1010495010

Recommended Procedure1. Air in Fuel System With air in the fuel system the engine will normally be difficult to start, run rough and release a large amount of white smoke. Remove the air from the fuel system by either loosening the cap on the tee at the fuel filter or by loosening the fuel line nuts one at a time at the cylinder heads. Turn the engine with the starter until the fuel flow at this connection is free of air. If air is not removed in this way, put 5 psi (0,35 kg/cm2) [CAUTION do not use more than 8 psi (0,56 kg/cm2)] of air pressure to the fuel tank and check for leaks at connections between the fuel tank and the fuel transfer pump. If there are no leaks at the connections, remove the fuel supply line from the tank and connect it to an outside fuel supply. If this corrects the problem the suction line (standpipe) inside the fuel tank has a leak.2. Valve Adjustment Not Correct Check and make necessary adjustments as per Testing and Adjusting section of the Service Manual. Intake valve adjustment is .015 in. (0,38 mm) and exhaust valve adjustment is .025 in. (0,64 mm).3. Fuel Injection Timing Not Correct Check and make necessary adjustments as per Testing and Adjusting section of the Service Manual.4. Automatic Timing Advance Does Not Operate Correctly Check with engine warm. Use the 1P3500 Timing Light Group. Special Instruction (SMHS6964) gives the test procedure. If the timing light is not available, make rapid "acceleration" (increase in speed) from low idle to high idle. Engine must have smooth acceleration. A timing advance that does not operate correctly can cause delays of the engine acceleration at some rpm before high idle, or possibly cause the engine to run rough and have exhaust noise (backfire) during acceleration. This condition is difficult to find if engine acceleration is slow or at a constant engine rpm.5. Bad Fuel Nozzle(s) Find a bad nozzle by running engine at the rpm range where it runs rough. Loosen the fuel line nut at the cylinder head enough to stop fuel supply to that cylinder. Each cylinder must be checked this way. If a cylinder is found where loosening of the nut makes no difference in the rough running, test the nozzle for that cylinder. To test a nozzle, remove the nozzle from the engine and test as per Testing and Adjusting section of the Service Manual.6. Valve Leakage; Wear or Damage to Pistons and/or Piston Rings; Wear or Damage to Cylinder Walls Check with the cylinder leakage tester. If leakage is over specification and leaking is heard at the air inlet to the engine (intake valve leaks), exhaust manifold (exhaust valve leaks), or at the oil filler opening (leaking past piston rings). Special Instruction (GMG00694) gives the test procedure.7. Cylinder Head Gasket Leakage Check with the cylinder leakage tester. If leakage is higher than specification, check at the fuel nozzle hole of the