101603-2231 ZEXEL F 01G 09U 03Y BOSCH INJECTION-PUMP ASSEMBLY f01g09u03y 1016032231 220009011a

*The serial number is above the fuel injection pump on the block.(1) Cylinder head bolts and nuts tightening procedure:1. Put engine oil on the threads of bolts and nuts. Tighten all bolts and nuts in number sequence to a torque of ... 45 N m (35 lb ft)2. Tighten all bolts and nuts in number sequence to a torque of ... 95 N m (70 lb ft)3. Again tighten all bolts and nuts in number sequence to a final torque of ... 135 N m (100 lb ft) Retighten the cylinder head bolts and nuts after the engine has run under part load for approximately thirty minutes.a. If the bolts and nuts move before the correct final torque is reached, retighten everything in the sequence shown to the following: 4.236 Engines ... 135 N m (100 lb ft)T4.236 Engines ... 120 N m (88 lb ft)b. If the bolts and nuts do not move before the correct final torque is reached, back each one off 30 to 60° (with an 8T3052 Degree Wheel) and retighten again, in the sequence shown, to the torque shown in Step a. After all the bolts and nuts are retightened, check the first 10 positions to make sure they are tightened to the correct torque. c. After 25 to 50 hours of service for a new or rebuilt engine, retorque the cylinder head bolts as shown in Step a above and adjust the valves again. New cylinder blocks have been introduced on the 4.236 and T4.236 engines. The new cylinder blocks have deeper cylinder head bolt holes and longer bolts. The old and new sizes are shown. The change became effective at engine serial number LDU027631M and up for the 4.236 engines and engine serial number LJU027774M and up for the T4.236 engines. The engine serial number is located above the fuel injection pump on the block. The new cylinder head bolts are not interchangeable between old and new blocks.(2) Torque for nuts that hold injectors ... 17 N m (12 lb ft) Replace the copper washer and rubber seal between the head and the injector every time the injector is removed. See Fuel Injector Installation in Testing And Adjusting.(3) Torque for fuel line nuts ... 20 N m (15 lb ft)(4) Torque for nuts or bolts that hold rocker shaft ... 43 N m (32 lb ft)(5) Clearance (cold), between rocker arm and valves (valve clearance): Intake ... 0.30 mm (.012 in)Exhaust ... 0.30 mm (.012 in)(6) Maximum permissible nozzle projection below cylinder head face after skimming ... 4.45 mm (.175 in) Skimming allowance (maximum) ... 0.30 mm (.012 in)(7) Depth of cylinder head (new) ... 103.188 0.38 mm (4.0625 .015 in) Minimum depth of cylinder head (after skimming) ... 102.502 mm (4.0355 in)Maximum permissible amount of bow (curve of cylinder head):Across width (transverse) ... 0.08 mm (.003 in)Across length (longitudinal) ... 0.15 mm (.006 in)See Cylinder Head Check in Testing And Adjusting.T4.236 Engines