101602-4670 ZEXEL 9 400 610 582 BOSCH INJECTION-PUMP ASSEMBLY 9400610582 1016024670 1156020740

* Be sure to orient the oil grooves as indicated above, otherwise seizures may occur in the engine.
* Use oversize thrust plates when adjusting the crankshaft end play. The upper and lower thrust plates on the same side must be of the same size. The thrust plates on one side may differ in size from those on the other side. Installation: Main bearings
* The upper main bearing has an oil hole while the lower main bearing does not. Do not confuse the two, as incorrect installation can cause seizures in the engine.
* Select and use a main bearing set of a thickness that can accommodate the inside diameter of each main bearing fitting hole between the upper crankcase and lower crankcase and the diameter of the corresponding crankshaft journal. Select the appropriate main bearing set by one of the two following methods.(1) Measurement based selection* Mount the upper crankcase on the lower crankcase without fitting main bearings. * Tighten the main cap bolts to 20 N m {2.0 kgf m}.* Measure the inside diameter of the main bearing fitting hole between the upper crankcase and lower crankcase (vertically from one point), and the diameter of the crankshaft journal (vertically or horizontally from one point).* Select a main bearing set that matches the measurements from the table below. If the color identification mark is indiscernible, measure the thickness of the bearing walls and use the measurements in its place. (Unit: mm) (2) Color identification mark based method* The crankshaft, upper crankcase, and main bearing can be appropriately combined in the following ways according to their color identification marks: No. 1: Position of color identification mark on No. 1 journalNo. 2: Position of color identification mark on No. 2 journalNo. 3: Position of color identification mark on No. 3 journalNo. 4: Position of color identification mark on No. 4 journalNo. 5: Position of color identification mark on No. 5 journal Installation: Lower crankcase
* Before installing the main cap bolt, check the punch marks on each bolt's head. (Bolts with one or two punch marks can be reused.)* The punch marks indicate the number of times each main cap bolt has been tightened using the torque-turn tightening method. Any main cap bolt that already has three punch marks must be replaced.
* Clean the sealant application surfaces of each part. * Apply a bead of sealant to the upper crankcase evenly and without any breaks as shown in the illustration.* Install the lower crankcase within three minutes of applying the sealant to the upper crankcase, being careful not to dislodge the sealant.* Apply engine oil to the threads and seating surface under the head of each of the main cap bolts, and tighten the bolts to a torque of 20 N m {2.0 kgf m} in the order indicated in the illustration (1 to 10). * Then, tighten the main cap bolts further by 90 degrees in the same order.* Tighten them by another 90 degrees in the same order.* After completing