101603-0511 ZEXEL 9 400 615 004 BOSCH INJECTION-PUMP ASSEMBLY 9400615004 1016030511 1156017841

Rework Procedure
Replacement of Diesel Oxidation Catalyst (DOC)
1. Remove three 222-8823 Bolts and three 232-3209 Washers to separate the 360-8875 Bellows Tube Assembly from the 360-8849 Catalytic Converter Group. Refer to Image1.1.1.
Image1.1.1
2. Loosen the clamp. Remove the DOC from the Catalytic Converter Group. Refer to Images1.2.1 and 1.2.2.
Image1.2.1
Image1.2.2
3. Remove the ring from the DOC. Remove the clamp from the catalytic converter. Refer to Images1.3.1 and 1.3.2.
Image1.3.1
Image1.3.2
4. Remove the five screws and five washers from the insulation around the DOC. Remove insulation from the DOC. The insulation will be reused. Refer to Images1.4.1 and 1.4.2.
Image1.4.1
Image1.4.2
5. Install the insulation that was removed from the old DOC on the new DOC. Refer to Image1.5.1.
Image1.5.1
6. Clean the sealing surface of the DOC flange. Clean the sealing surface of the flange on the catalytic converter group. Clean the ring that was removed from the old DOC. Refer to Images1.6.1, 1.6.2, and 1.6.3
Image1.6.1
Image1.6.2
Image1.6.3
7. Apply seal paste to both sides of the ring, to the flange surfaces of the new DOC, and the catalytic converter. Refer to Image1.7.1.
Note: Make sure to cover the complete ring and flange surfaces with seal paste when applying it.
Image1.7.1
8. Place the ring on the flange of the new DOC. Position the new DOC against the catalytic converter. Refer to Images1.8.1 and 1.8.2.
Image1.8.1
Image1.8.2
9. Orient the DOC so that it will line up correctly with the bellows tube. Install and orient the clamp in order to hold the new DOC in place. Apply sealing paste or high temperature grease to the bolt of the clamp. Tighten the clamp. Then reattach the DOC to the bellows tube. Refer to Image1.9.1.
Image1.9.1
10. Tap the clamp around the circumference to properly seat the clamp. Tighten the clamp to a specified torque of 18 N.m (13.3 ft-lb). Apply sealing paste or high temperature grease to the three 222-8823 Bolts to assemble the bellows. Refer to Image1.10.1.
Image1.10.1
11. Please write down the number of active regenerations. This number can be found in the Monitor Service Menu in the Aftertreatment Status section. Please enter this information to the claim story when you submit your claim. Refer to Image1.11.1.
Image1.11.1