Cover Gasket, Replacing

COVER GASKET, REPLACING





NOTE:
- The numbered items in the procedure that follows refer to illustration above.
- Removing return spring and throttle lever. Throttle Lever and Return Spring. Replacing





- Mark position of fuel delivery adjusting screw (e.g. position of screw slot relative to pump cover -arrows-).
- Loosen lock nut, rotate against locking sleeve and unscrew fuel delivery adjusting screw from pump cover.

CAUTION:
- The slightest misadjustment of the fuel delivery adjusting screw can cause soot build-up and/or loss of engine power.
- It is important that the adjusting screw is reinstalled in the same position. The fuel delivery adjusting screw should NEVER be rotated past the starting position.

- Disconnect fuel return line.
- Using an oil can, draw fuel out of injection pump through return line connection.
- Remove 4 bolts fastening cover.
- Separate idle speed adjustment rod -26- from idle speed boost lever -20- by removing circlip -1-.
- Raise pump cover -5-; press throttle lever shaft -12- toward inside of cover (e.g. with handle of screwdriver) when removing cover.
- Disconnect spring -8- (e.g. with shop-made wire hook).





- Remove pump cover and press out bearing bushing -9-.
- Clean pump cover.





- Coat outer diameter of new bearing bushing with D6 and press into cover as far as collar.
- Carefully remove any surplus D6.

NOTE: Various types of bushing are available depending on the pump version. Select the correct type by comparing with the old one.

- Install new O-ring -10- for throttle lever.
- Insert new gasket -13- for pump cover (sealing ring is held in place during installation by small protrusions around outside of gasket).
- Moisten throttle lever shaft and O-ring with diesel fuel and press into bearing bushing, then install on pump cover.

CAUTION: Make sure that the thrust washer -11- for the throttle lever is in position.

- Attach spring -8-.
- Tighten pump cover.
- Screw in fuel delivery adjusting screw -27- with new O-ring.
- Install return spring and throttle lever.
- Run engine until warm and check idle speed and maximum engine speed.