101603-4002 ZEXEL 9 400 615 067 BOSCH INJECTION-PUMP ASSEMBLY 9400615067 1016034002 1156018925

Start By:a. remove oil pump1. Check the connecting rods and caps for their identification and location. 2. Turn the crankshaft until the connecting rod caps are in position.3. Remove two bolts (1) and the cap from the connecting rod. Remove the lower half of the bearing from the cap.4. Push the connecting rod away from the crankshaft. Remove the upper half of the bearing from the connecting rod. Install the bearings dry when the clearance checks are made. Put clean engine oil on the bearings for final assembly.5. Install the upper half of the bearing in the connecting rod.6. Pull the connecting rod slowly on to the crankshaft.7. Install the lower half of the bearing in the cap. Be sure the tabs in the back of bearings are in the tab grooves of the connecting rod and cap.The serviceman must be very careful to use Plastigage, Tool (A) correctly. The following points must be remembered:Make sure that the backs of the bearings and the bores are clean and dry.Make sure that the bearing locking tabs are properly seated in their slots.The crankshaft must be free of oil where the Plastigage touches it.Put a piece of Plastigage (A) on the crown of the bearing half that is in the cap. Do not allow the Plastigage to extend over the edge of the bearing.Install the bearing cap using the correct torque-turn specifications. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed.Do not turn the crankshaft with the Plastigage installed.Carefully remove the cap but do not remove the Plastigage. Measure the width of the Plastigage while it is in the bearing cap or on the crankshaft journal. Do this by using the correct scale on the package. Record the measurements.Remove the Plastigage before reinstalling the cap.When using Plastigage, the readings can sometimes be unclear. For example, all parts of the Plastigage are not the same width. Measure the major widths to make sure that they are within the specification range. Also, experience has shown that when checking clearances tighter than 0.10 mm (.004 in) the readings may be low by 0.013 to 0.025 mm (.0005 to .0010 in). Out-of-round journals can give faulty readings. Also, journal taper may be indicated when one end of the Plastigage is wider that the other.For complete details concerning measuring bearing clearance, see the topic, "Engine Bearings & Crankshafts", SEBD0531. 8. Use Plastigage (A) to check the bearing clearance.9. Put Plastigage (A) on the bearing.10. Put 2P2506 Thread Lubricant on the threads of the rod bolts and seat surfaces of the nuts. Be sure the cylinder numbers on the rod cap and rod are the same and are on the same side of connecting rod. Numbers are on the same side of the rod and cap as are the bearing tab slots. If new rods are installed, put the cylinder number on the rod and cap. Do not turn the crankshaft when Plastigage (A) is in position.