101402-1004 ZEXEL 9 400 613 844 BOSCH INJECTION-PUMP ASSEMBLY 9400613844 1014021004 me080749

Parts Required For 4C-8180 Timing Tool Group
Refer to Chart A for item identification.Assemble and Set the 4C-8180 Timing Tool Group
1. Obtain a 108-2104 Plunger and Barrel Assembly. This part can be new or used. If the part is used, make sure it is in good working condition. The plunger should move freely in the barrel.
4C-8181 Timing Tool Assembly
(9) 8J-3819 Spring. (10) 1N-3257 Retainer Ring. (11) Plunger and barrel from 108-2104 Plunger and Barrel Assembly. (12) 4C-8178 Indicator Mount Bonnet. (14) 4C-8179 Bonnet Nut. (16) 2W-3429 Gear Segment (part of 108-2104). (17) 8N-0669 Bolt (part of 108-2104). (18) 4P-8704 Spring (part of 108-2104). (19) 9Y-2088 Washer.2. Make a 4C-8181 Timing Tool Assembly out of the 108-2104 Plunger and Barrel Assembly. The 4C-8181 Timing Tool Assembly is not a serviceable part. a. Remove and discard 8N-0669 Bolt (17), 2W-3429 Gear Segment (16), and 4P-8704 Spring (18) from the 108-2104 Plunger and Barrel Assembly.b. Assemble 8J-3819 Spring (9) and 9Y-2088 Washer (19) onto plunger. The 9Y-2088 Washer is part of the 108-2104 Plunger and Barrel Assembly.c. Install the 4C-8178 Indicator Mount Bonnet (12) onto the barrel using a 1N-3257 Retainer Ring (10).d. Slip 4C-8179 Bonnet Nut (14) over indicator mount bonnet (12).e. This tool is now a 4C-8181 Timing Tool Assembly (11).3. Assemble knurled gauge collar (3) onto gauge (5) by threading them together. Hand tighten the two parts. Make sure the gauging surfaces are clean and free of all debris, nicks, etc.4. Install 4C-8181 Timing Tool Assembly (11) into gauge collar (3).5. Thread bonnet nut (14) into gauge collar (3) and hand tighten with 9U-5120 Spanner Wrench (13). This will secure timing tool assembly (11) into gauge collar (3).6. Spring (9) on the timing tool assembly should make the end of the plunger extend approximately 30 mm (1.2 in) past the end of gauge (5).7. Push on the end of the plunger and make sure it travels freely (under spring force) in and out of the gauge block bore. If there is binding, disassemble and correct the problem.8. Install either a 5P-4814 Collet (6) or 4C-2982 Collet Assembly (7) into indicator mount bonnet (12).9. Install an indicator with a 5P-7262 Contact Point into collet (6 or 7). Use either a 6V-6106 Dial Indicator or an 8T-1002 Probe connected to an 8T-1001 Electronic Position Indicator.
Do not over tighten collet (6 or 7) holding the indicator. Over-tightening can result in damage to the indicator or the electronic position indicator probe.
10. Tighten collet (6 or 7) just enough to make sure the indicator or electronic position indicator probe will not move in collet.11. Zero the indicator by following this procedure. a. Place the 4C-8183 Gauge Plate (8) onto a flat surface.b. Carefully hold the entire 4C-8180 Timing Tool Group and place it on the gauge plate, with the end of the plunger contacting the plate.c. Push down on the entire assembly, compressing the spring, until the bottom of gauge (5) is in complete contact with gauge plate (8).
Zero The Timing Tool Assembly With