Diesel injection pump, servicing: Notes

The following injection pump components can be replaced:

• Throttle lever/return spring. See DIESEL INJECTION PUMP THROTTLE LEVER/RETURN SPRING, REMOVING AND INSTALLING 
• Throttle lever bushing - 9 -, throttle lever O-ring - 10 - and gasket - 13 - between pump cover and housing. See THROTTLE LEVER BUSHING IN PUMP COVER, PUMP COVER GASKET AND O-RING FOR THROTTLE LEVER SHAFT, REPLACING 
• O-ring - 24 - for residual fuel delivery adjusting screw. See O-RING FOR RESIDUAL FUEL DELIVERY ADJUSTING SCREW, REPLACING 
• O-ring for idle speed boost shaft. See O-RING FOR IDLE SPEED BOOST SHAFT, REPLACING 
• O-ring - 15 - for Injection Start Positioner -N165-. See O-RING FOR IDLE SPEED BOOST SHAFT, REPLACING 
• O-rings - 34 - and - 37 - for CSA lever and cover. See O-RINGS FOR COLD START ACCELERATOR (CSA) LEVER AND COVER, REPLACING 

The following list pertains to Fig 1 .

1. Circlip 
   • Pry off with screwdriver
2. Compression spring 
3. Upper spring plate 
4. 10 Nm (7 ft lb) 
5. Pump cover 
6. Thrust washer 
7. Shaft 
   • For idle speed boost
8. Idle speed boost spring 
   • Detach when removing pump cover
   • Do not overstretch
9. Bearing bushing 
   • Replace, see THROTTLE LEVER BUSHING IN PUMP COVER, PUMP COVER GASKET AND O -RING FOR THROTTLE LEVER SHAFT, REPLACING 
10. O-ring 
    • Always replace
11. Thrust washer 
12. Throttle lever shaft 
    • Press out with handle of screwdriver
13. Gasket 
    • Always replace (see THROTTLE LEVER BUSHING IN PUMP COVER, PUMP COVER GASKET AND O -RING FOR THROTTLE LEVER SHAFT, REPLACING  ) without replacing bearing
14. Shim 
15. O-ring 
    • Always replace, see O-RING FOR IDLE SPEED BOOST SHAFT, REPLACING 
16. Injection timing spring 
17. Injection timing cover with Injection Start Positioner - N165- 
18. 10 Nm (7 ft lb) 
19. 10 Nm (7 ft lb) 
20. Idle speed throttle lever 
21. Lower spring cover 
22. Thrust ring 
23. O-ring 
    • Always replace, see THROTTLE LEVER BUSHING IN PUMP COVER, PUMP COVER GASKET AND O -RING FOR THROTTLE LEVER SHAFT, REPLACING 
24. O-ring 
    • Always replace, see O-RING FOR RESIDUAL FUEL DELIVERY ADJUSTING SCREW, REPLACING 
25. Washer 
26. Adjustment rod 
    • For idle speed
27. Fuel delivery adjusting screw 
    • Mark installation position
28. Circlip 
29. Spring washer 
30. Washer 
31. Cold Start Accelerator (CSA) lever 
    • Mark installation position
32. Retainer 
    • For CSA lever - 31 -
33. Thrust ring 
34. O-ring 
    • Always replace, see O-RINGS FOR COLD START ACCELERATOR (CSA) LEVER AND COVER, REPLACING 
35. 10 Nm (7 ft lb) 
36. Cover 
    • For CSA mechanism
37. O-ring 
    • Always replace, see O-RINGS FOR COLD START ACCELERATOR (CSA) LEVER AND COVER, REPLACING 
Fig 1: Exploded View Of Diesel Injection Pump Components