101402-4010 ZEXEL 9 400 613 886 BOSCH INJECTION-PUMP ASSEMBLY 9400613886 1014024010 8943440260

(1) Torque for three studs to hold the water pump ... 27 4 N m (20 3 lb.ft.)(2) Plug (two on front and two on rear). Put 5P3413 Pipe Sealant on the threads of the plugs.(3) Length of dowels (four) out of the block face ... 18.5 0.5 mm (.73 .02 in.)(4) Thickness of the gasket between the cylinder block and top plates ... 0.21 0.03 mm (.008 .001 in.)(5) Thickness of the top plates ... 8.59 0.03 mm (.338 .001 in.)(6) Make reference to Cylinder Liner Projection, for the height of the liner.(7) Bore in the block for the camshaft bearings (seven bores) ... 76.835 0.018 mm (3.0250 .0007 in.)(8) Torque for one plug on front and two on rear of the block ... 80 14 N m (60 10 lb.ft.)Put 5P3413 Pipe Sealant on the threads of the plug.(9) Bore in the block for the main bearings (with main bearing caps torqued):Standard, original size (new) ... 129.891 0.013 mm (5.1138 .0005 in.)0.64 mm (.025 in.) larger than original size ... 130.526 0.013 mm (5.1388 .0005 in.)(10) Projection of dowels (four) out of the front and rear faces of the block ... 19.0 0.5 mm (.75 .02 in.)(11) Width of slot for bearing cap ... 215.900 0.013 mm (8.5000 .0005 in.)Width of bearing cap ... 215.900 0.013 mm (8.5000 .0005 in.)Clearance between slot and bearing cap (with main bearing caps torqued) 0.025 mm (.0010 in.) tight to 0.025 mm (.0010 in.) loose(12) Torque for the bolts that hold the piston cooling tubes ... 24 7 N m (18 5 lb.ft.)(13) Torque for the bolts that hold the caps for the main bearings:Install the main bearing caps with the marks (arrow) toward the front of the engine. Each cap has a number on the bottom and must be installed in the same position as the correct number on the left side of the block pan rail.a. Put 2P2506 Thread Lubricant on the threads of the bolts.b. Tighten the bolts on left (tab) side to ... 260 14 N m (190 10 lb.ft.)c. Tighten the bolts on right side to ... 260 14 N m (190 10 lb.ft.)d. Put a mark on each bolt and cap.e. Tighten the bolts on right side, from the mark ... 120°f. Tighten the bolts on left side, from the mark ... 120° (14) Dimension (new) from the centerline of crankshaft bearing bore to top of block (top deck) ... 419.10 0.15 mm (16.00 .006 in.)(15) Dimension (new) from centerline of crankshaft bearing bore to bottom of block (pan rails) ... 165.10 0.10 mm (6.500 .004 in.)
Right Side Of Engine(16) Plug. Two plugs - one located at front and the other located at rear of right cylinder bank.(17) Plug. Use 6V1541 Quick Cure Primer and 9S3265 Retaining Compound in the plug bores