159237-5500 ZEXEL 9 421 611 590 BOSCH CAPSULE 9421611590 1592375500 1157297960

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This is an illustration of the 154-8016 Fuel Injector Seals . (14) Metal Seal (15) 133-3715 Backup Ring (16) 150-4105 Backup Ring (17) 9X-7557 O-Ring Seal (18) 148-2903 O-Ring Seal (19) 149-5240 Backup Ring (20) 109-3207 O-Ring Seal
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(A) 149-2955 Seal Protector
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(B) 149-2956 Seal Installer
The correct procedures and tooling specifications must always be used. Failure to follow any of the procedures may result in damage, malfunction, or possible engine failure.
Note: Install the upper seal pack first. Then install the middle seal pack. Finally, install the bottom O-Ring Seal.
Both the 149-2955 Seal Protector (A) and the 149-2956 Seal Installer (B) should be used when you are installing the upper high pressure seals.Note: New seals should be installed after each removal of the injector from the engine.
Lubricate the O-Ring seals and the sleeve bore of the injector sparingly with clean engine oil.Note: Proper installation of the injector is very important. Damage to the upper high pressure seals can cause excessive oil leakage under the valve cover. This may cause the engine not to start due to a low actuation pressure. Damage to the lower high pressure seals may allow high pressure oil to leak into the fuel supply passage. This will result in excessive oil consumption.
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(X) 8T-2396 Bolts . (Y) 159-0288 Deflector . Note: Some of these engines were built without the 159-0288 Deflector . During the installation of the unit injectors, the deflectors should be installed. Six 159-0288 Deflectors and six 8T-2396 Bolts are required for each engine. These new deflectors and bolts replace the former 6V-8653 Bolts .
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(C) 152-1057 Fuel Injector Installer
Carefully install the injector into the injector bore. If access permits you to seat the injector, push the injector straight down on top of the injector's solenoid by hand until the injector is firmly seated in the injector bore. Pushing hard enough to compress the injector's seals may be difficult. If the injector can not be seated by hand, use a 152-1057 Fuel Injector Installer (C). Note: Do NOT pry on the top of the injector with another tool. Do NOT strike the injector with a hammer. Damage to the injector will result. Damage to the injector that is due to improper installation is not a warrantable failure.
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(2) Wiring Harness Connection (3) Clamp (10) Shoulder Bolt (11) Socket Head BoltNote: Do not use the shoulder bolt and the socket head bolt in order to seat the injector. If a side load is placed on the bolts, the bolts may fail.
After the injector is seated, position the clamp (2) and tighten the Shoulder Bolt (10) to a torque of 6 N m (50 lb in). Then tighten the Socket Head Bolt (11) to a torque of 12 N m (9 lb ft).
Insert the harness connectors (2) back into the injectors' solenoids. Ensure that the clips are snapped back into