104304-3062 ZEXEL 9 400 616 499 BOSCH INJECTION-PUMP ASSEMBLY 9400616499 1043043062 5156013592

1. Disconnect fuel line (3) from the fuel transfer pump. Cap or plug immediately.2. Disconnect fuel line (4) from the fuel transfer pump. Cap or plug immediately.3. Remove bolts (1).4. Remove fuel transfer pump (2). Check the condition of the O-ring seal on the fuel transfer pump. If necessary, make a replacement. Put clean engine oil on the O-ring seal when assembling fuel transfer pump. For installation of the fuel transfer pump, reverse the removal steps.Disassemble & Assemble Fuel Transfer Pump
Start By:a. remove fuel transfer pump 1. Remove seal (1) from the fuel transfer pump.
Cover (2) is under spring tension. Remove the bolts that hold cover (2) slowly to prevent injury.
2. Remove bolts (3) and cover (2) the housing. 3. Remove seals (4) and valve (5) from cover (2). 4. Remove spring (6) from the piston.
Mark the orientation of valve (8) as to its location in the housing.
5. Remove washer (7) and valve (8) from the housing. 6. Remove piston (9) and sleeve (10) from the housing. 7. Remove seal (11) from sleeve (12). 8. Remove guide and tappet assembly (13) from the housing. 9. Remove seal (14) from guide (15).
If tappet (17) or guide (15) are damaged or worn, they must be replaced as a unit.
10. Remove ring (16) from tappet (17) and the tappet from guide (15). 11. Remove the bolts and cover (18) from the housing. 12. Remove seal (19) from cover (18). 13. Remove valve (20) from the housing. The following steps are for the assembly of the fuel transfer pump.14. Install valve (20) in the housing. Put clean fuel on seal (19) and install it on cover (18). Install the cover on the housing.15. Install tappet (17) in guide (15). Install ring (16) on tappet (17) to hold the tappet in the guide.16. Put clean fuel on seal (14) and install it on the guide and tappet assembly (13). Install guide and tappet assembly (13) in the housing.17. Put clean fuel on seal (11) and install it on sleeve (12). Install sleeve (12) in the housing.18. Install piston (9) in the housing. Install valve (8) and washer (7) in the housing. Install spring (6) in the piston.19. Install valve (5) in cover (2).20. Put clean fuel on seals (4) and put them in position on cover (2). Install cover (2) on the housing.21. Put seal (1) in position on the fuel transfer pump.End By:a. install fuel transfer pump