101603-6041 ZEXEL INJECTION-PUMP ASSEMBLY Cross 1016036041 me035644

Parts Location
Illustration 2 g01663154
Exploded view (1) 304-1108 Diesel Particulate Filter Gp (2) 304-1111 Bracket As (3) 253-4495 Clamp As (4) 277-4718 Clamp As (5) 8T-4121 Hard Washer (6) 8T-4196 Bolt (7) 5P-8245 Hard Washer (8) 6V-3823 Bolt (9) 3B-4508 Lockwasher (10) 6V-8149 Nut Installation Procedure
Diesel Particulate Filter Installation
Illustration 3 g01606033
Typical example (16) Exhaust pipe assembly (17) Clamp (18) 241-9265 Muffler Clamp (19) Pipe assembly (20) Bracket assembly (21) Support assembly (22) Muffler assembly (23) Hard washer (24) Bolt (25) Plate (26) Bolt (27) Hard washer (28) Plate (29) Washer (30) Bolt
Remove existing muffler assembly (22) and bracket assembly (20). Set aside exhaust pipe assembly (16), clamp (17), three hard washers (23), three bolts (24), three bolts (26), three hard washers (27), two washers (29), and two bolts (30). These parts will be reused in later steps.
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Reuse three bolts (24) and three hard washers (23) that were used to secure the former bracket assembly (20) to secure the new 304-1111 Bracket As (2) to support assembly (21). Refer to Illustrations 3 and 4.
Reuse two bolts (30) and two washers (29) that were used to secure the former bracket assembly (20) to secure the new bracket assembly (2) to plate (28). Refer to Illustrations 3 and 4.
Reuse three bolts (26) and three hard washers (27) that were used to secure the former bracket assembly (20) to secure the new bracket assembly (2) to plate (25). Refer to Illustrations 3 and 4.
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(3) 253-4495 Clamp As (5) 8T-4121 Hard Washer (6) 8T-4196 Bolt
Install the two new 253-4495 Clamp As (3) by using four 8T-4196 Bolts (6) and four 8T-4121 Hard Washers (5). Loosely secure these bolts so that the clamp assembly is adjustable. Refer to Illustration 5.
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(1) 304-1108 Diesel Particulate Filter Gp (3) Clamp assembly (31) Inlet module tube
Install the new 304-1108 Diesel Particulate Filter Gp (1) on top of clamp assembly (3). Make sure that the inlet module tube (31) fits into pipe assembly (19). Use a new 241-9265 Muffler Clamp (11) to secure the joint.
Illustration 7 g01602273
(4) 277-4718 Clamp As (7) 5P-8245 Hard Washer (8) 6V-3823 Bolt (9) 3B-4508 Lockwasher (10) 6V-8149 Nut
Once you have the pipe assembly installed properly, tighten each bottom clamp assembly (3). Install the top 277-4718 Clamp As (4) by using four 5P-8245 Hard Washers (7) and four 6V-3823 Bolts (8). Use four 3B-4508 Lockwashers (9) and four 6V-8149 Nuts (10) on clamp assembly (3) side. Refer to Illustration 7.
Install exhaust pipe assembly (16) that you removed from the muffler assembly (22) to the outlet module tube of the DPF and secure the joint with existing clamp (17) that you removed from the muffler assembly.
Reconnect the drain lines.
Insulate pipe assembly (19) from the turbo end to the inlet