101608-6330 ZEXEL 9 400 619 503 BOSCH INJECTION-PUMP ASSEMBLY 9400619503 1016086330

Fig. 37-Injection Line to Injection Pump Screw TorqueConnect injection lines to injection pump using NEW washers (Fig. 37).Injection line to injection pump screw torque ... 35 lb-ft(47 N m)
Fig. 38-Fuel Supply and Return LinesConnect fuel supply line (1, Fig. 38) and fuel return line (2).Fuel supply line connection torque (1) ... 20 lb-ft(27 N m)Fuel return line connection torque (2) ... 20 lb-ft(27 N m)Connect throttle linkage, remove timing window, and install timing hole cover.Bleed the fuel system (Group 0413).See Group 9010 for adjustments.4-239T, 4-276T, 6-359T, 6-414D or 6-414T Engine
Position number one piston at top dead center on compression stroke.
Fig. 39-19918 Timing WindowRemove timing hole cover and install 19918 Timing Window (Fig. 39) on injection pump.Check pump mounting flange packing for damage or wear. Replace if necessary.
Fig. 40-Injection Pump Timing LinesRotate pump drive shaft and align timing lines (Fig. 40) on governor weight retainer and cam ring.Position pump on engine front plate making sure Woodruff key enters drive gear.
Fig. 41-Injection Pump Drive Gear NutInstall washer and nut on oiled pump drive shaft (Fig. 41).Injection pump drive gear nut torque (oiled) ... 150 lb-ft(203 N m)
Fig. 42-Injection Pump Attaching NutsInstall pump attaching nuts (Fig. 42) finger tight.Rotate injection pump housing counterclockwise (viewed from flywheel end) as far as possible.Rotate crankshaft counterclockwise (viewed from front end) approximately 180°. Reverse rotation and reposition number one piston at top dead center on compression stroke.Rotate injection pump housing clockwise (viewed from flywheel end) until timing lines align.Tighten injection pump attaching nuts (Fig. 42).Injection pump attaching nut torque ... 20 lb-ft(27 N m)Rotate crankshaft counterclockwise (viewed from front end) approximately 180°. Reverse rotation and reposition number one piston at top dead center on compression stroke.Injection pump timing lines should be aligned. If not, retime injection pump.
Fig. 43-Fuel Supply and Return LinesConnect fuel supply line (1, Fig. 43), fuel return line (2) and fuel injection lines (3).Fuel line connection torque (1) ... 20 lb-ft(27 N m)Fuel return line ... 20 lb-ft(27 N m)Fuel injection line connector torque ... 20 lb-ft(27 N m)Connect throttle linkage, remove timing window, and install timing hole cover.Bleed the fuel system (Group 0413).See Group 9010 for adjustments.Bleeding
Fig. 44-Fuel Filter Bleed ScrewLoosen fuel filter bleed screw (Fig. 44).
Fig. 45-Fuel Transfer Pump Primer LeverPump primer lever (Fig. 45), located on fuel transfer pump, until no air flows from bleed screw.Tighten the bleed screw.All Engines Except 3-179D
Fig. 46-Fuel Supply Line ConnectionSlightly crack fuel supply line connection at injection pump (Fig. 46) and pump primer lever until no air flows from fuel supply line connection.Tighten fuel supply line connection to 20 lb-ft (27 N m).Leave primer lever positioned toward the cylinder block.Loosen each nozzle inlet connector and turn engine until fuel flows form connector.Tighten nozzle inlet connector to 35 lb-ft (47 N m).3-179D Engine
If engine will not start after bleeding fuel filter, bleed fuel injection pump as follows:
Fig. 47-Roto-Diesel Fuel Injection Pump Bleed ScrewsLoosen lower bleed screw (B, Fig. 47).Pump primer lever on fuel transfer pump until fuel