101402-3961 ZEXEL 9 400 611 495 BOSCH INJECTION-PUMP ASSEMBLY 9400611495 1014023961 3863644

(1) Install pin to get a dimension of ... 4.78 0.25 mm (.188 .010 in.)(2) Install dowel to get a dimension of ... 12.19 0.25 mm (.480 .010 in.)(3) Rack bearing alignment. The center of the rack bearing tab must be within 0.05 mm (.002 in.) of a vertical line that: (a) goes through the center of the rack bearing(b) is parallel to the vertical centerline of injection pump housing The following tooling is available to position the rack bearings correctly: 5P6217 Fixture and 5P6218 Driver.The correct bearing depth [19.0 0.5 mm (.75 .02 in.)] is controlled when driver is stopped by fixture.(4) Position of camshaft bearing joints (X) must be limited to area (A) ... 30 1° When viewed from the Front of the injection pump housing, all three camshaft bearings must be installed with the bearing joint (X) in an area (A) between a vertical position and a position 30° to the Right of vertical. At the same time, oil hole (Y) in the two end bearings (center bearing has no oil hole) must be to the Left of vertical.(5) Distance from bottom of housing to end of rear hollow dowel ... 1.5 0.3 mm (.06 .01 in.)(6) Maximum distance from bottom of housing to end of front hollow dowel ... 1.0 mm (.04 in.)(7) Torque for bolts ... 55 7 N m (40 5 lb.ft.)(8) Distance from rear bearing bore face to installed rear camshaft bearing ... 4.8 0.5 mm (.19 .02 in.)(9) Distance from front bearing bore face to installed front camshaft bearing ... 1.0 0.5 mm (.04 .02 in.) (10) Distance from top surface of housing to top of lower governor drive bearing ... 28.4 0.5 mm (1.12 .02 in.)(11) Install top governor drive bearing (notch end up) with sharp corner even with top surface of housing. Position center of notch so that it is in alignment with the center of oil pressure relief hole (Z) by an amount of ... 10°(12) Install dowel to get a dimension from centerline of fuel injection pump bore to dowel (seal dowel holes with aluminum ball) ... 14.76 0.10 mm (.581 .004 in.)(13) Distance from end of bearing to face of boss on housing ... 73.03 0.51 mm (2.875 .020 in.)(14) Distance between the bearings for the shaft ... 34.80 0.51 mm (1.370 .020 in.)(15) Install pins until they contact bottom of housing casting.