104640-2224 ZEXEL 9 461 614 440 BOSCH FUEL-INJECTION PUMP 9461614440 1046402224

Before any service work is done on the fuel system, the outer surface of the injection pump housing must be clean.
1. Remove the plug from location (1). Install tool (A) in the hole with the large diameter end without the taper down. Move the governor control to the "ON" position until the rack stops against tool (A). The racks are now in center (zero) position.2. Disconnect lines (2) from the fuel injection pumps. Remove the washers. Put caps on all fuel openings. 3. Remove bushings (3) with tooling (B). 4. Install tooling (C). Hold the fuel racks in the center (zero) position and carefully remove the fuel injection pump.
When injection pumps, spacers and lifters are removed from the injection pump housing, keep the parts of each pump together so they can be installed back in their original location.
5. Remove spacers (4) from the fuel injection pump housing.
Be careful when the injection pumps are disassembled. Do not cause damage to the surface on the plunger. The plunger and barrel for each pump are made as a set. Do not put the plunger of one pump in the barrel of another pump. If one part has wear, install a complete new pump assembly. Be careful when the plunger is put into the bore of the barrel.
Do not remove gear segment (15) from plunger (10).
6. Remove plunger (10), washer (14) and spring (9) from barrel (8).7. Remove ring (12) from barrel (8) and bonnet (11).8. Remove spring (6), collar (7) and check valve assembly (13) from bonnet (11). Do not disassemble check valve assembly (13).9. Keep seal (5) with the bonnet for use at assembly.Install Fuel Injection Pumps
Make sure the fuel racks are in the center (ZERO) position before the fuel injection pumps are installed.1. Put diesel fuel on all parts to be assembled. 2. Put spring (2), collar (3) and check valve assembly (9) in position in the bonnet.
Do not slide barrel (4) against the check valve assembly when it is assembled. Scratches on the check valve can cause it to leak.
3. Put the bonnet assembly (7) and barrel (4) in position and install ring (8).4. Install spring (5), washer (10) and plunger assembly (6). 5. Put spacer (12) in position in the pump housing bore. Make sure the correct spacer is with each pump. The lobe on the cam must be at its lowest position for easy installation of the fuel injection pumps.6. Hold the fuel racks in the center (ZERO) position when the fuel pumps are installed. Put the space in gear segment (11) in alignment with the groove in barrel (4). 7. Put the injection pump straight down into the housing bore so the space in the gear segment is in alignment with pin (13) and the groove in the barrel is in alignment with dowel (14). Use tool (B) to install the pump. 8. Install seal (1) and bushing (15) in the pump housing bore. If the pump is in the correct position, bushing (15) will