101603-8073 ZEXEL 9 400 615 240 BOSCH INJECTION-PUMP ASSEMBLY 9400615240 1016038073 8943938534

1. Remove five bolts (1) that hold oil lines bracket and supports to the engine.2. Remove three bolts (2) that hold oil pump to the engine.3. Remove the oil pump with the lines as a unit from under the engine. 4. Remove oil lines (3) from the oil pump.Install Oil Pump (Brakesaver)
1. Put clean SAE 30 engine oil on the O-ring seals. Connect the oil lines in the oil pump. Install the bolt and washer that holds the line in the pump.2. Put the oil pump and the oil lines as a unit in position under the engine.3. Install the three bolts that hold the pump to the engine. Make sure the oil pump gear is engaged with crankshaft gear.4. Install the five bolts that hold the oil lines bracket and support to the engine.end by:a) install oil panDisassemble Oil Pump (Brakesaver)
start by:a) remove oil pump1. Remove bolt and washer that hold gear on the shaft. 2. Use tooling (A) to remove drive gear (1) from shaft. Remove the key from shaft. Put marks on the pump bodies so they can be assembled in the correct position.3. Remove retainer (3) for bypass valve. Remove spring and bypass valve. 4. Remove bolts (4) that hold pump body (2) to the main pump body. Remove the pump body (2).5. Use tooling (B) to remove the bearings from pump body (2). 6. Remove the gears (7). Put marks on the gears so they can be assembled in the same position.7. Remove the spacer (6) from the main oil pump body (5). Use tooling (C) to remove the bearings from spacer (6).8. Remove the gears from main pump body (5). 9. Use tooling (C) to remove the bearings from the main pump body.Assemble Oil Pump (Brakesaver)
1. Use tooling (A) to install the bearings (2) until they are even with the outside surface of the main pump body (1). Install the bearings (2) so the junctions in the bearings are 30° 15° from the center of the bearing bores and toward the oil pump outlet passage as shown. 2. Use tooling (A) to install the bearings (3) in the spacer. Install the bearings until they are in position an equal distance in from each side of the spacer. Install the bearings with the oil holes in the bearings in alignment with the oil holes in the spacer and the junctions in the bearings in alignment with the cavity in the spacer as shown. 3. Put clean engine oil on all gears and bearings before they are assembled in the oil pump. Install the idler and drive gears (5) in the main pump body.4. Install the spacer (4) on the gear shafts with the smaller cavity out and the oil holes in the spacer toward the pump outlet passage as shown. 5. Use tooling (B) to install the bearings (6) in the pump body (7) until they are .060 .010 in. (1.52 0.25 mm) from the inside edge of the bearing