101492-1061 ZEXEL 9 400 614 423 BOSCH INJECTION-PUMP ASSEMBLY 9400614423 1014921061 me017863

Start By:a. remove oil pump 1. Check each connecting rod cap for its location on the crankshaft. Each cap must have a number (1) which is the same as the number on the connecting rod. Do not mix bearings.2. Turn the crankshaft until two of the pistons are at bottom center.3. Remove connecting rod caps (2). Remove the lower bearing from the connecting rod caps.4. Push the connecting rods away from the crankshaft and remove the upper bearings from the connecting rods.
Be careful not to damage the crankshaft journals. Do not turn the crankshaft while any of the connecting rod caps are removed.
5. Install the upper bearings in connecting rods. put clean engine oil on the bearings and on the crankshaft journals. Slowly pull the connecting rods on the crankshaft.6. Put clean oil on the lower bearings. Install the lower bearings in the connecting rod caps. Be sure tab (3) on the back of the bearings fits in the groove of the caps and connecting rods. 7. Check the bearing clearance with Plastigage (A) as follows:a. Put clean oil on the threads of bolts (4). Install caps (5), Tool (A) and nuts finger tight.b. Tighten each nut (6) to a torque of 80 8 N m (60 6 lb ft).c. Put a mark across the nuts and bolts. Tighten the nuts 120 degrees more. 8. Remove caps (5) and Plastigage (A). Make sure the connecting rod bearing caps are installed with their identification number in arrangement with the connecting rod number.
Do not use an impact wrench to tighten the nuts the additional 120 degrees.
9. Measure the thickness of the Plastigage to find the bearing clearance. the clearance for new bearings must be 0.071 to 0.168 mm (.0028 to .0066 in). The maximum clearance for used bearings is 0.25 mm (0.010 in).10. Install caps (5). Tighten nuts (6) to a torque of 80 8 N m (60 6 lb ft). Tighten the nuts 120 degrees more.11. Do Steps 1 through 10 for the other connecting rod bearings.End By:a. install oil pump