101603-8592 ZEXEL 9 400 610 665 BOSCH INJECTION-PUMP ASSEMBLY 9400610665 1016038592 8943959192

start by:a) remove fuel shutoff solenoidb) remove fuel ratio control1. Make a setting of the fuel injection pump timing as follows: a) Turn the engine clockwise (as seen from the front of the engine) with tool (B) to top center of the compression stroke of No. 1 piston. See FINDING TOP CENTER COMPRESSION POSITION FOR NO. 1 PISTON in TESTING AND ADJUSTING. b) Remove the plug from the side of fuel injection pump housing. Install tool (A) through the hole in pump housing and into the notch in the injection pump camshaft. If tool (A) can not be installed in the notch of the injection pump camshaft, the injection pump is not in time with the engine and the following procedure must be followed: a) Remove nuts (1). Remove cover (2) for the automatic timing advance.b) Loosen bolt (3) and hit the bolt with a soft hammer to loosen the automatic timing advance. c) Remove bolt (3) and washer (4). Install the bolt again.d) Turn the fuel injection pump drive shaft clockwise with bolt (3) until tool (A) can be put into the notch in the injection pump camshaft.e) Remove the bolt. Install washer (4) and bolt (3) so the washer is loose.
TYPICAL EXAMPLEf) Remove the timing bolt from the flywheel. Turn the engine 60° counterclockwise (as seen from the front of the engine) with tool (B).g) Tighten the bolt that holds the automatic timing advance by hand. Turn the engine clockwise (as seen from the front of the engine) with tool (B) until the engine is at top center compression stroke of No. 1 piston.h) Tighten bolt (3) to a torque of 15 lb.ft. (20 N m). Remove tool (A) from the fuel injection pump housing. Tighten bolt (3) to a torque of 110 10 lb.ft. (149 14 N m).
Do not tighten the bolt to final torque until tool (A) is removed.
i) Turn the crankshaft counterclockwise (as seen from the front of the engine) two complete revolutions and check the timing to see that timing is correct.j) If timing is not correct, do the above procedure again.k) Install the cover for the automatic timing advance and the nuts that hold it. 2. Disconnect fuel lines (5) and (7) from the fuel injection pump housing.3. Disconnect fuel injection lines (9) from the fuel injection pump housing. Install caps and plugs in all fuel line openings.4. Remove two bolts (8) that hold bracket (6) to the governor housing. 5. Fasten a nylon strap and a hoist to the fuel injection pump housing. Remove bolts (12) and (10) that hold the fuel injection pump housing to the cylinder block.6. Remove bolts (11) that hold the fuel injection pump housing to the fuel injection pump and governor drive housing.7. Remove fuel injection pump housing and governor. The weight is 70 lb. (32 kg).Remove Fuel Injection Pump Housing And Governor (Later)
start by:a) remove fuel shutoff solenoidb) remove fuel ratio control1. Make a setting of the fuel injection pump timing as