101601-5401 ZEXEL 9 400 614 612 BOSCH INJECTION-PUMP ASSEMBLY 9400614612 1016015401 220801480a

1. Install the turbocharger on tool (A) as shown.2. Put alignment marks on three housings of the turbocharger for correct alignment during assembly. Loosen clamp (2), and remove the clamp and housing (1) from housing assembly (3). 3. Loosen clamp (4), and remove housing assembly (3) from housing (5). 4. Put the cartridge group in position in tool (B) as shown.
When the nut is loosened, do not put a side force on the shaft. This can result in a bent shaft.
5. Use a 5S9566 Sliding T-Wrench and a universal socket (6) to remove the nut that holds the compressor wheel to the wheel assembly.6. Remove compressor wheel (7) and the shims from wheel assembly (8).7. Remove housing assembly (3) from wheel assembly (8). 8. Remove ring (9) and backplate (10) from wheel assembly (8). 9. Use tool (C), and remove snap ring (11) from housing assembly (3). 10. Remove insert (12) and sleeve (13) from housing assembly (3). 11. Remove ring (14) from sleeve (13). 12. Remove two screws (15) and deflector (16) from housing assembly (3). 13. Remove ring (18) and bearing assembly (17) from the housing assembly. 14. Remove sleeve (19) and ring (20) from the housing assembly. 15. Remove O-ring seal (23) from the housing assembly.16. Use tool (D), and remove snap ring (22) from the housing assembly.17. Remove bearing (21). Remove the snap ring behind the bearing with tool (D). 18. Use tool (D), and remove snap ring (25) from the housing assembly.19. Remove bearing (24). Remove the snap ring behind the bearing with tool (D).20. Check all the parts of the turbocharger for damage. If the parts are damaged, use new parts for replacement. See Special Instruction, Form No. SMHS6854 for Turbocharger Reconditioning. Also see Guidelines For Reusable Parts, Form No. SEBF8018.Assemble Turbocharger
1. Make sure that all of the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material. Do not put oil on any parts of the turbocharger until after the compressor wheel has been installed. After the turbocharger has been assembled, pour clean engine oil into the oil inlet of the turbocharger.
Make sure that the snap rings that hold bearings (24) and (21) in position in housing assembly (3) are installed with the round edge of the outside diameter toward the bearing.
2. Install the snap ring behind bearing (24) with tool (D).3. Install bearing (24) in housing assembly (3).4. Use tool (D), and install snap ring (25) in the housing assembly. 5. Install the snap ring behind bearing (21) with tool (D).6. Install bearing (21) in the housing assembly.7. Use tool (D), and install snap ring (22) in the housing assembly. 8. Put wheel assembly (8) in position on tool (B) as shown.9. Put backplate (10) in position on the wheel assembly. Put 6V2055 High Vacuum Grease in the groove for seal ring (9) at assembly to one half or more of the depth of the groove all the way around.10. Install ring (9) in