101602-9491 ZEXEL 9 400 614 975 BOSCH INJECTION-PUMP ASSEMBLY 9400614975 1016029491

(1) Endplay for shaft (new) ... 0.102 0.025 mm (.004 .001 in) Maximum permissible endplay (worn) ... 0.20 mm (.008 in)(2) Thickness of thrust bearing (where thrust rings contact bearing) ... 5.36 0.03 mm (.211 .001 in)(3) Diameter of shaft (new) ... 12.697 to 12.705 mm (.4999 to .5002 in) Bore in the bearing (new) ... 12.741 to 12.748 mm (.5016 to .5019 in)Maximum permissible clearance between bearing and shaft (worn) ... 0.05 mm (.002 in)(4) Maximum permissible gap of oil seal ring, measured in bore of housing ... 0.25 mm (.010 in)
The impeller shaft nut is a left hand thread (CCW).
(5) Install the compressor wheel (at room temperature) as follows: a. Put compressor wheel on the shaft.b. Put a small amount of clean engine oil on the threads.c. Tighten the nut (CCW) to 14 to 17 N m (125 to 150 lb in).d. Loosen the nut and tighten again to 9 N m (80 lb in) plus an additional 60 degrees (1/6 turn).
Do not bend or add stress to the shaft when the nut is loosened or tightened.
(6) Thickness of each thrust ring ... 2.553 0.013 mm (.1005 .0005 in)(7) Bore in housing (new) ... 20.744 to 20.757 mm (.8167 to .8172 in) Outside diameter of the bearing (new) ... 20.630 to 20.643 mm (.8122 to .8127 in)Maximum permissible clearance between bearing and bore in housing (worn) ... 0.15 mm (.006 in)Torque for four nuts (put 5P3931 Anti-Seize Compound on threads) and bolts that hold turbocharger to exhaust manifold ... 55 5 N m (40 4 lb ft)Install the band clamps to hold the cartridge to the compressor housing as follows: a. Tighten clamps to 14 1.1 N m (125 10 lb in)b. Tap (hit) clamp lightly all around.c. Tighten again to ... 14 1.1 N m (125 10 lb in) Put clean engine oil in the oil inlet of the turbocharger after assembly or before installation to provide start up lubrication and/or storage protection.