103682-0542 ZEXEL 9 400 613 107 BOSCH INJECTION-PUMP ASSEMBLY 9400613107 1036820542 6162732740

Introduction
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.There have been isolated occurrences of excessive fuel leakage past the electronic unit injectors on some engines.Accelerated wear on the delivery valve results in an increased leak rate. The high pressure pump cannot generate enough fuel flow or volume to compensate for the leakoff rates above the critical value 38 mL (1.3 oz) per 30 seconds of cranking for six cylinder engines at a speed of 150 rpm. The high pressure pump cannot generate enough fuel flow or volume to compensate for the leakoff rates above the critical value 25 mL (0.85 oz) per 30 seconds of cranking for four cylinder engines at a speed of 150 rpm.If the engine turns over but the engine does not start, refer to Troubleshooting, "Engine Cranks but Will Not Start".Test Procedure
Before begining any work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information.Refer to Systems Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     334-3221     Fuel Leakoff Kit     1    
Ensure that the engine is shut down.
Illustration 1 g02103090
Injector harness
Disconnect the injector harness (1) from the front of the engine.
Illustration 2 g02103093
Typical exampleNote: Direct any leaking fuel into a suitable container.
Remove the bolt (2) from the "fuel relief block" and save the bolt for reinstallation.
Illustration 3 g02103095
Fuel leakoff kit (A) Tooling (3) Clear plastic hose
Install tooling (A) to the "fuel relief block".
Slide the tooling through the banjo bolt in order to replace the bolt that was removed in the previous step.
Thread the tooling into the "fuel relief block" and slightly tighten the tooling.
Connect a plastic hose (3) onto the tooling. Place the opposite end of the plastic hose into a suitable container that is clean.
Crank the engine with the starting motor for 30 seconds.
Record the amount of fuel that has been collected. Conduct the test three times. Calculate the average of the three values.
For six cylinder engines, if more than 38 mL (1.3 oz) of fuel has been collected during the 30 second crank test, then there is high leakoff of the electronic unit injectors. For four cylinder engines, if more than 25 mL (0.85 oz) of fuel has been collected during the 30 second crank test, then there is high leakoff of the electronic unit injectors. If this is the case, replace the electronic unit injectors and the fuel injection lines. Return the original electronic unit injectors and the fuel injection lines to the parts return center.
For six cylinder