101603-8081 ZEXEL 9 400 615 241 BOSCH INJECTION-PUMP ASSEMBLY 9400615241 1016038081 8943939201

3. Remove bearing caps (1) from the two connecting rods. Put pieces of rubber hose or tape on the threads of the connecting rod bolts as protection for the crankshaft. 4. Push the pistons up until the piston rings are clear of the cylinder liner. Remove pistons (2). Keep each cap with its connecting rod.
Do not turn the crankshaft while any of the connecting rods are in the engine without the caps installed. Do not cause damage to the cooling tubes when the pistons are removed.
5. Do Steps 1 through 4 for the remainder of the pistons.Install Pistons
1. Put clean engine oil on the piston rings and cylinder liners. 2. Put two pistons in position opposite of each other in the correct bore of the block. Install pistons (1) with tool (A).
Make sure that the pistons are installed with flat surfaces (2) of the connecting rods toward each other and the chamfered sides (4) toward the crankshaft.
For more detail about the installation of connecting rod bearings see REMOVE AND INSTALL CONNECTING ROD BEARINGS.3. Check the bearing clearances with tool (B). 4. Put clean engine oil on bolts (5) and the connecting rod bearings. Install caps (3) and nuts finger tight. Tighten each nut to a torque of 60 6 lb.ft. (80 8 N m). Put a mark across the nuts and bolts. Tighten each nut 120° more.5. Check the side clearance between two connecting rods on the same crankshaft journal. Clearance must be .011 to .033 in. (0.28 to 0.84 mm) for new rods.6. Do Steps 1 through 5 for the remainder of the pistons.