101602-8030 ZEXEL 9 400 610 611 BOSCH INJECTION-PUMP ASSEMBLY 9400610611 1016028030 1156030830

Checking Field Coil for Insulation(3) Inspecting the stator coil(a) Check for conduction between lead wires of the stator coil. If there is no conduction, the stator coil is suspected to be broken. Replace the stator coil.
Checking Stator Coil for Conduction(b) Check for conduction between each lead wire and stator core. If any conduction is found, the stator coil is suspected to be poor in insulation. Replace the stator coil.
Checking Stator Coil for InsulationAssembly of Alternator
Reassemble the alternator assembly in the reverse order of disassembly, giving care to the following:(1) The rear bearing has an eccentric groove. Install the snap ring so that its projection fits in with the deepest part of the groove.(2) When installing a new rear bearing, press-fit the bearing with its groove facing the slip ring side.(3) When press-fitting the rear bearing into the rear bracket, heat the bracket. CAUTION* Pass a wire through the small hole in the rear bracket to lift the brushes before installing the rotor to the rear bracket. Remove the wire after the rotor is installed.
Lifting BrushesInstallation
Install the alternator in the reverse order of removal.(1) Insertion of spacerWhen installing the support bolts, insert the spacer in place using the following procedure:(a) Push in the support bolts to the normal position. (Leave the nuts removed from the bolts.)(b) Push the alternator backward. Measure the clearance between the alternator rear bracket and gear case bracket to determine the number of spacers to be inserted into the clearance (0.2 mm maximum).(c) Reinstall the alternator with the necessary spacer inserted in place. Tighten the support bolt nuts securely.(d) Perform the belt tension adjustment.
Inserting SpacerDynamo, Regulator and Rectifier
Specifications
For specifications, see 7-01.Inspection
(1) Checking the unit in serviceMeasure battery voltage across terminals with a circuit tester. It is considered normal if no-load measurement is kept steady at about 15.0V at 5000rpm or more of alternator speed.
Measuring Voltage Across Battery Terminals(2) Checking the regulator aloneTo judge whether the regulator itself is acceptable or not, check the regulator for normal conduction by connecting the circuit tester to the lead wires as follows. For testing, use the circuit tester as an ohmmeter.
Lead Outlet CouplerInstallation
(1) Heat affects largely on the regulator and rectifier. Position them in a well-ventilated place. Install the regulator in proper direction so that the outlet of leads from the body faces downward.GLOW PLUG
Removal and Installation
Glow plug tightening torque: 1.5 - 2.0 kgmInspection
Check for conduction between the glow plug terminal and body. If the plug is not conductive at all or shows a large resistance, replace the plug.
Checking Glow PlugKEY-OFF STOP SYSTEM
General
The function of this system is to actuate the fuel cutoff solenoid when the starter key is placed in the OFF position. It also has the emergency engine stop function by actuating the control timer in case of abnormal lowering of oil pressure (and abnormal increase of coolant temperature for special-specification engines).Control Timer Unit
Timer UnitFuel Cutoff Solenoid (Push type)
(1) Specification
Fuel Cutoff Solenoid (Push type)(2) Solenoid installation procedure(a) Temporarily fit the solenoid (1) and nut (2) to the