Bosch Injection Pump Reassembly
This has some tricky bits...
Install the new gasket into the groove in the lid.
Mark and unscrew the maximum fuel screw nearly all the way out. It makes reassembly easier. This is a critical adjustment so ensure you mark carefully or count threads to ensure it goes back exactly.
Place the throttle linkage into the lid as shown below. Ensure the flats in the shaft are vertical as these have to engage with the slot on the governor lever.. Hook the fast idle spring onto it's location and ensure the throttle linkage sits between the emergency stop lever forks.
Bring the lid to the body at an angle so the throttle lever sits just above its slot in the governor lever.
Tilt the lid further back and manipulate the throttle rod into the slot. You may have to rotate it slightly and push/pull it by gently rotating the throttle spindle to bring the flats into line, allowing it to drop into the slot.
Once the rod is in the slot, rotate it to ensure it cannot pop out again. Now hook the fast idle spring onto the governor lever.
Now carefully bring the lid over the projecting governor lever that makes contact with the maximum delivery screw and manoeuvre the lid into place, nothing that there is a dowel on one fixing hole.
With the lid nearly home, rotate the throttle spindle to ensure the throttle linkage is still firmly slotted into the governor lever.
Adjust the maximum fuel screw back to its former position and reassemble the throttle actuation lever. Note that the lever is best fully fitted before trying to hook the very strong return spring back on.
Now is an ideal time to complete the job fully and replace the Distributor Head Seal
Page last updated 12 April 2008
Job Done, The End!...