104229-0003 ZEXEL 9 410 617 691 BOSCH FUEL-INJECTION PUMP 9410617691 1042290003

Possible Causes/Corrections Air Or Water In Fuel SystemWith air in the fuel system, the engine will normally be difficult to start, run rough, and release a large amount of white smoke. If the engine will not start, loosen a fuel injection line nut at the through the head adapter and crank the engine until fuel comes out. Tighten the fuel line nut. Start the engine. If the engine does not run smooth or releases a large amount of white smoke, loosen the fuel line nuts one at a time at the through the head adapters until the fuel that comes out is free of air. Tighten the fuel line nuts. If the air cannot be removed in this way, put 35 kPa (5 psi) of air pressure to the fuel tank.
Do not use more than 55 kPa (8 psi) of air pressure in the fuel tank or damage to the tank may result.
Check for leaks at the connection between the fuel tank and the fuel transfer pump. If leaks are found, tighten the connections or replace the lines. If there are no visual leaks, remove the fuel supply line from the tank and connect it to an outside furl supply. If this corrects the problem, the suction line (standpipe) inside the fuel tank has a leak.Water in the fuel can cause rough running and possible fuel system damage. Valve Adjustment Not CorrectCheck and make necessary adjustments as in Testing And Adjusting Section of the Service Manual. Intake valve lash is 0.38 mm (.015 in) and exhaust valve lash is 0.64 mm (.025 in). Also check for a bent or broken push rod. Defective Fuel Nozzle(s)Find a defective nozzle by running engine at the rpm where it runs rough. Loosen the fuel line nut at the through the head adapter 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 in Testing and Adjusting Section of this Service Manual. Fuel Leakage From Fuel Injection Line NutTighten nut to 40 7 N m (30 5 lb ft). Again check for leakage. Be sure to check fuel injection lines inside valve cover base. Defective Fuel Injection PumpAn injection pump can have a good fuel flow coming from it but cause rough running because of slow timing that is caused by wear on the bottom end of the plunger. See the Testing and Adjusting Section in this Service Manual for the correct specifications and procedure to check plungers and lifters.Fuel pumps which are severely scored from debris can cause rough running but fuel dilution usually occurs before horsepower is affected.Low installation torque on the fuel pump retaining nut can cause misfire, rough running and low power. Fuel Has A High "Cloud Point"In cold weather operation this condition should