101603-2592 ZEXEL 9 400 615 057 BOSCH INJECTION-PUMP ASSEMBLY 9400615057 1016032592 220401452a

1. Remove the bolts (2) that hold suction bell and tubes (1) to the engine block. 2. Remove O-ring seals (3) from the tubes. Inspect O-ring seals for damage. Make a replacement if necessary. 3. Remove clip (5) and then remove screen (4). Clean the screen if necessary. 4. Remove the bolts (7) that hold the oil pump to the engine block. Remove oil pump (6).Install Oil Pump
1. Put the oil pump (1) in position on the engine block and install the bolts that hold it. 2. Install screen (2) with the clip (3) that holds it. 3. Put a small amount of clean oil on O-ring seals (4). Install the O-ring seals on the tubes. 4. Put tubes (5) in position in the oil pump.5. Put suction bell (6) and support in position on the engine block and install the four bolts that hold it.End By:a. install oil panDisassemble Oil Pump
Start By:a. remove oil pump 1. Remove bolts (1) and cover (2). Remove spacer from cover, then remove spring and plunger from pump bore. 2. Remove bolt (4), washer (3) and gear (5) from the pump. 3. Remove bolts (7) then remove shaft assembly (6) from the pump. 4. Remove bolts (8) then remove cover assembly (9) from the pump body. 5. Use Tooling (A) to remove bearings (10) from cover assembly (9). 6. Remove shaft and gear assembly (11) from the pump body. 7. Remove bolt and washer from gear (12). Use Tool (B) to remove gear (12) 8. Remove shaft and gear assembly (13) from the pump body. 9. Use Tooling (A) to remove bearings from pump body bore.Assemble Oil Pump
1. Use Tooling (A) to install bearings (2) until they are even with the outside surface of main pump body (1). Install bearings (2) so the junctions in the bearings are 30 15 degrees from the center line of the bearing bores and toward the oil pump outlet passage as shown. 2. Install shaft and gear assembly (3) in the pump body. Install key in shaft. 3. Install gear (4) on the shaft. Install bolt and washer on the shaft. 4. Install shaft and gear assembly (5) in the pump body. 5. Install bearings (7) in the cover assembly (6) with Tooling (A). Install the bearings until they are in position the same distance in from each side of the cover assembly. Install the bearings with the oil holes in the bearings in alignment with the oil holes in the cover assembly and the junctions in the bearings in alignment with the cavity in the cover assembly. 6. Install cover assembly (6) on the pump body. 7. Install shaft assembly (8) on the oil pump body with the two bolts that hold it. 8. Install gear (9) on shaft assembly. Install washer and bolt on gear (9). 9. Install plunger (10), spring (13) and spacer (11) in the pump body. Install cover (12) and the bolts (14) that hold it.End By:a. install oil pump