101603-7882 ZEXEL 9 400 615 223 BOSCH INJECTION-PUMP ASSEMBLY 9400615223 1016037882 8943934643

Firing order (injection sequence) ... 1,8,4,3,6,5,7,2Injection timing before TC (top center): Precombustion Chamber (PC) ... 11 1°Direct Injection (DI) ... 28 1°(1) Torque for bushing ... 150 10 lb.ft.205 14 N m)(2) 1S7592 Lifter Spring: Length under test force ... 38.66 mm (1.522 in.)Test force ... 100 5 N (22.6 1.1 lb.)Free length after test ... 44.48 mm (1.751 in.)Outside diameter ... 25.27 mm (.995 in.)(2) 7N1208 Lifter Spring: Length under test force ... 29.26 mm (1.152 in.)Test Force ... 325 16 N (73.0 3.6 lb.)Free length after test ... 48.03 mm (1.891 in.)Outside diameter ... 25.27 mm (.995 in.)(3) 1S8634 Check Valve Spring for PC Engines: Length under test force ... 8.15 mm (.321 in.)Test force ... 0.85 0.04 N (.19 .01 lb.)Free length after test ... 10.77 mm (.424 in)Outside diameter ... 9.86 mm (.388 in.)(3) 6N24 Check Valve Spring for DI Engines: Length under test force ... 9.53 mm (.375 in.)Test force ... 56 3 N (12.5 .6 lb.)Free length after test ... 13.03 mm (.513 in.)Outside diameter ... 11.68 mm (.460 in.)(3) 8N1415 Spring For Reverse Flow Check Valve on Later DI Engines: Length under test force ... 8.69 mm (.342 in.)Test force ... 111 6 N (25 1 lb.)Free length after test ... 12.12 mm (.477 in.)Outside diameter ... 9.78 mm (.385 in.)(4) Thickness of spacers: 9N6496 Spacer ... 4.12 mm (.162 in.)9N6495 Spacer ... 4.22 mm (.166 in)5M2697 Spacer ... 4.32 mm (.170 in.)2M4208 Spacer ... 4.42 mm (.174 in.)2M4209 Spacer ... 4.52 mm (.178 in.)2M4210 Spacer ... 4.62 mm (.182 in.)2M4211 Spacer ... 4.72 mm (.186 in.)2M4212 Spacer ... 4.83 mm (.190 in.)5M2691 Spacer ... 4.93 mm (.194 in.)5S7189 Spacer ... 5.03 mm (.198 in.)(5) Bores for the racks: Bore in housing, at the rear (new) ... 12.758 0.038 mm (.5023 .0015 in.)Bearing at the front (new) ... 12.758 0.046 mm (.5023 .0018 in.)Diameter of fuel racks (new) ... 12.662 0.005 mm (.4985 .0002 in.)Maximum permissible clearance between rack and bearings (worn) ... 0.18 mm (.007 in.)(6) Bore in bearings for the camshaft (new) ... 53.988 0.038 mm (2.1255 .0005 in.) Diameter of bearing surfaces of the camshaft (new) ... 53.899 0.013 mm (2.1220 .0005 in.)Maximum permissible clearance between the bearings and the camshaft ... 0.25 mm (.010 in.)(7) Length of injection pump plunger. (8) Timing dimension for fuel injection pump. Use 6V7926 Indicator Group with 5P4158 Gauge (A) to measure this dimension.