104645-3500 ZEXEL 9 461 615 543 BOSCH FUEL-INJECTION PUMP 9461615543 1046453500

Illustration 3 g01077676
(1) HEUI pump (2) Fuel transfer pump (9) Service bolt (10) Seals (11) Seal (12) Check valve assemblies (Qty 7)Removing the Check Valve Assemblies from the HEUI Pump
Remove the two high pressure seals (10). Discard the two seals. Refer to Illustration 3.Note: Take caution in order to avoid wiping any debris into the pump.
Remove the seal (11) from the bearing on the fuel transfer pump. Discard the seal. Refer to Illustration 3.
Remove the seven check valve assemblies (12) from the HEUI pump by using Tooling (A). Refer to Illustration 3.Note: Take caution in order to avoid wiping any debris into the pump.
Inspect all check valve assemblies (12) for broken springs by using the following procedure.
Place the flat end of the check valve on a work bench so that the valve is positioned vertically.
Press on the check valve poppet (13) with a small cross tip screwdriver and then release the check valve poppet. There should be some resistance from the spring in the check valve. The poppet should return to the initial position after releasing. Refer to Illustration 4.
Illustration 4 g01077708
(12) Check valve assembly (13) Check valve poppet
If any of the valve springs are broken, do not advance. Stop the rework procedure. Replace the HEUI pump.
If none of the valve springs are broken, proceed to the next section.Installing Check Valve Assemblies into the HEUI Pump
Install seven new 254-4302 Check Valve Assemblies (12) that are found in the 254-4334 Check Valve Kit .
Insert the check valve assemblies by hand and press on the back of the valve until the valve is fully seated in the barrel.
Tighten each valve to 9.0 1.5 N m (80 13 lb in) by using an appropriate torque wrench and Tooling (A) .Note: The check valve assemblies must be torqued to the correct specifications. Failing to apply the correct torque could result in loosening of the valve or cracking of the valve in the field.
In order to ensure that all valves are torqued, repeat Step 3.Installing the Fuel Transfer Pump onto the HEUI Pump
Install the two new 239-2402 Seals (10) on the back face of the HEUI pump (1). Refer to Illustration 5.
Illustration 5 g01077898
(1) HEUI pump (10) 239-2402 Seals
Install a new 179-8128 Seal (11) on the fuel transfer pump (2). Refer to Illustration 6. Use 1U-6396 O-Ring Assembly Compound in order to hold the seal in place during assembly. Ensure that the seal is completely seated.
Illustration 6 g01077908
(2) Fuel transfer pump (11) 179-8128 Seal
Do not remove the service bolt. Position the fuel transfer pump on the HEUI pump. Be sure to properly align the drive tang on the fuel transfer pump with the drive slot on the HEUI pump.Note: Failure to align the drive tang prior to the installation of the fuel transfer pump will not allow proper assembly of the two pumps.
Install the three mounting bolts (7) for the fuel transfer pump (2). Tighten the bolts to a torque of 4.0 0.2 N m (35 1.5