104264-5090 ZEXEL 9 410 617 244 BOSCH FUEL-INJECTION PUMP 9410617244 1042645090

Introduction
Do not perform any procedure in this Special Instruction until you read this information and you understand this information.This Special Instruction is intended to provide instructions on installing O-Ring seals on the injector sleeves.Required Parts
Table 1
Required Parts    
Part Number     Part Name     Quantity    
227-1200     Injector Sleeve     6    
310-7255     O-Ring Seal     6    
310-7257     O-Ring Seal     6    Required Tools
Table 2
Required Tools    
Part Number     Part Name     Quantity    
221-9777     Sleeve Installer     1    
4C-5552     Large Bore Brush     1    
4C-9507     Retaining Compound     1    Cleaning the Injector Sleeves and Installing O-Ring Seal
Note: Thoroughly clean the injector sleeves with the 4C-5552 Large Bore Brush .Note: Thoroughly clean the bore in the cylinder head for the injector sleeves with the 4C-5552 Large Bore Brush .Note: Do not apply any lubricant to the O-ring seals.
Illustration 1 g01379557
(1) 310-7255 O-Ring Seal (2) 310-7257 O-Ring Seal (3) 227-1200 Injector Sleeve
Install the upper O-Ring (1) on the injector sleeve (3) .Note: The upper O-Ring is dark blue.
Install the lower O-Ring (2) on the injector sleeve (3) .Note: The lower O-Ring (2) is turquoise.
Position the injector sleeve on the 221-9777 Sleeve Installer .
Apply a thin coat of 4C-9507 Retaining Compound around the outer circumference of area (A). Ensure that the retaining compound does not make contact with the O-Ring seal at any time.
Position the injector sleeve (3) in the cylinder head by using the 221-9777 Sleeve Installer .
Slowly push the injector sleeve into the cylinder head by gently tapping with a hammer.Note: Allow the 4C-9507 Retaining Compound to cure for two hours at 21 °C (70 °F) before filling the engine with coolant. Longer curing time is required for lower temperatures.
Install the unit injectors. Refer to Disassembly and Assembly, "Unit Injector-Install" to install the unit injectors.