JohnTurbo wrote:
Any guidance would be greatly appreciated. I'm great with petrol, but this diesel lark is far to bizarre!!
Well -
Diesel engines works with an entirely different combustion process than petrol. Thats why all pet engine experience is worth nowt on such a creature ...
Apart from the obvious fuel sucking inlet and the 4 timed pressurised injector outputs - the Bosch pump basically has these main externals :
1) A cold start device - which in
no way is comparable to a pet choke. It does not enrichen fuel. Instead it alters the injection timing and somewhat the engine idle speed. This is to prevent the cold engine stalling.
The cold start can be activated mechanically by a bowden cable from a thermo device or from a vacuum capsule.
Looks like the latter is exactly one of your questions.
Sometimes the mechanical coldstart device also controls a switch which in turn controls a corrector solonoid.
2) A fuel shut-off solonoid. This is the only means of stopping a diesel engine : cut the fuel supply (or obviously stalling the engine). Therefore an electrovalve is fitted inline with the fuel supply on the pump. The valve must be constantly feeded by +12V over the ignition switch while engine running (& starting).
Later types have build on electronic antitheft device exactly on this valve to prevent theft starting. By nature this is a very sturdy build-on with hardened steel etc.
3) A fuel enrichener controller - controlled by intercooler air pressure - to boost fuel when turbo pressure increases. Would look like a vacuum device.
4) Any auxillary device to control the idle speed in case of automatic gearbox, aircondition etc. This will most likely work on the acc arm idle rest.
Adjusting such a creature is however rather easy - assuming everything is working correct :
Coldstart is simply adjusted for elevated idle at cold engine - to some 1050rpm.
Idle is adjusted - with hot engine only - by adjusting the acc arm rest to some 850rpm
There would be a fuel volume set screw on the pump too. This should be locked to prevent fiddling with the fuel volume. Only on calibrating a pump for new applicatiuons it should be necessary to adjust this.
This is because even the slightest over-setting on this will make the engine a slow carbon producer (as seen in your rearview mirror).
You MUST have the injectors that were used with the pump you've got. You can NOT swap Bosch & CAV injectors.
The injectors are calibrated to work with the pump they are designed for.
Also this means that injectors/pumps from turbo and non-turbo can not be swapped.
Pumps & injectors same make from same engine types (i.e. a bosch pump for non-turbo 1.9L engine) should swap no problems.
And you can guess how I know that!! 
) and the original pump was a CAV and was replaced with a bosch off a 405 or was it the other way round 
, real bitsa job!! 