101606-9000 ZEXEL 9 400 615 549 BOSCH INJECTION-PUMP ASSEMBLY 9400615549 1016069000

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7. Possible Causes-Engine Will Not StartA. No Fuel In Tank(s)Visually check fuel level in the tank(s). Be sure the tank selection valve is open for the tank with fuel in it. Be sure the fuel line between the tanks (if more than one) is open.B. No Fuel From Unit Injectors1. Prime the fuel system per item 6B.2. If temperatures are below -12° C (10° F), a poor quality fuel can "wax" and cause a restriction in the system. Install a new fuel filter. It may be necessary to drain the entire fuel system and replace with No. 1 grade fuel, or a blend of fuel depending on the air temperature.3. Check for a fuel supply line restriction by removing the fuel supply line from the fuel filter base. 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.
If there is no flow or a weak flow of fuel from the supply line, clean or replace plugged lines.4. Check fuel transfer pump pumping gears and drive gear on the camshaft. Repair or replace as necessary. See 3176 Diesel Truck Engine Disassembly and Assembly, Form No. SENR3914.5. Drain the fuel manifold, remove each unit injector (see 3176 Diesel Truck Engine Disassembly and Assembly, Form No. SENR3914) and bench test unit injectors to check flow. Replace plugged unit injectors.Testing of the injectors must be done off of the engine. Use the 1U6661 Pop (Injector) Tester Group with a 1U6663 Injector Holding Block, and a 1U6665 Power Supply, to test the injectors. For the test procedure refer to Special Instruction, Form No. SEHS8867, Using The 1U6661 Pop (Injector) Tester. For test specifications refer to Special Instruction, Form No. SEHS8804, Unit Injector Test Specifications for 1.7 Liter Engines. Inspect and repair as necessary the sealing surface (seat) of the injector sleeve in the cylinder head when removing and installing an injector. The injector sealing surface (seat) must be free of scratches or evidence of combustion products. If it is necessary to rework (ream) or replace the sleeve use 4C4054 Tool Group and refer to Special Instruction, Form No. SEHS9120, Removal And Installation Of Unit Injector Sleeve.C. Restriction In Exhaust SystemLoosen the exhaust pipe from the exhaust manifold and start engine. If the engine starts easily, check the exhaust system for damage and/or restrictions.D. Electrical Problem Ahead Of Electronic Control Module (ECM)Check for a problem with the electrical supply to the ECM.Crankshaft Does Not Turn
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Possible Causes-Engine Will Not StartA. No Battery VoltageCheck battery voltage. If there is no battery voltage, put a charge to the battery. If battery will not hold a charge, load test the battery. Use the 6V4930 Battery Load Tester and make reference to Special Instruction, Form No. SEHS8268 for complete information on use of the 6V4930 Battery Load Tester.B. Defective Switch, Defective Wiring Or Connection In Switch CircuitWith the ignition switch in the "start"