101601-2660 ZEXEL INJECTION-PUMP ASSEMBLY Cross 1016012660 220003810a

2. Remove four bolts (2), nuts and cover that connect air inlet pipe (1) to the aftercooler cover.3. Put a mark on the turbocharger compressor housing in alignment with a mark on the turbocharger cartridge housing. Loosen the bolts for the turbocharger compressor housing. Carefully turn housing so air inlet pipe (1) is away from the aftercooler cover. 4. Remove bolts (3) that hold the aftercooler cover to the aftercooler base. Remove aftercooler cover (4). 5. Remove pipe (7), coupling, four bolts (5), elbow (6) and adapter (8).6. Remove the two brackets that hold the water inlet pipe to the timing gear cover. 7. Remove four bolts (9) and move elbow (10) and adapter (11) away from the aftercooler base.8. Remove the aftercooler core from the aftercooler base.Install Aftercooler Core
1. Install new O-ring seals (1) in the aftercooler core.2. Put aftercooler core (2) in position in the aftercooler base with the end that has the identification "Fresh Water" to the water inlet end of the aftercooler base. 3. Install a new O-ring seal on elbow (3). Put adapter (5) and elbow (3) in position on the aftercooler base and install four bolts (4). 4. Install new O-ring seals on elbow (7) and coupling (8).5. Install adapter (9), elbow (7), four bolts (6), coupling and pipe (10).6. Put the aftercooler cover in position on the aftercooler base and install the bolts that hold the cover to the base.7. Carefully turn the turbocharger compressor housing so the mark on the housing is in alignment with the mark on the turbocharger cartridge housing. Tighten the bolts for the compressor housing to 105 5 lb.in. (11.9 0.6 N m).
Do not cause damage to the O-ring seal between the turbocharger compressor housing and the cartridge housing.
8. Install the cover, four bolts (12) and nuts that connect air inlet pipe (11) to the aftercooler cover.9. Fill the engine with coolant.