101603-9292 ZEXEL 9 400 615 294 BOSCH INJECTION-PUMP ASSEMBLY 9400615294 1016039292 16700z5674

Illustration 2 g01132938
(1) HEUI pump (2) Fuel transfer pump (4) Drive gear (5) 227-5904 O-Ring Seal (6) Tie Bolt (7) Bolts for the fuel transfer pump (8) Tie Bolts (9) Location for temporary bolt (12) 185-3241 O-Ring Seal
Remove the single tie bolt (6) that is located in the top left corner of the pump by using Tooling (B). Refer to Illustration 2. Only remove the single tie bolt (6). Removing more bolts will result in damage to the pump.
Replace tie bolt (6) with the temporary bolt (9) that is provided in the service kit.Note: The temporary bolt that is provided in the kit has an undersized bolt head. The temporary bolt prevents the body of the HEUI pump from separating during service. Do not remove the temporary bolt until the fuel transfer pump has been completely reinstalled.
Tighten the temporary bolt (9) to 10 N m (7.4 lb ft) by using Tooling (C) .Note: Do not place an excessive torque on the temporary bolt. The aluminum housing of the pump could be damaged.
After installing the temporary bolt (9) in the top left location, remove the three bolts (7) that fasten the fuel transfer pump to the HEUI pump by using Tooling (A) .
Proceed by removing the remaining three tie bolts (8) by using Tooling (B) .
Illustration 3 g01132944
(1) HEUI pump (2) Fuel transfer pump (9) Temporary bolt (10) Seals (11) Seal
Separate the fuel transfer pump from the HEUI pump. Refer to Illustration 3.Installing the Fuel Transfer Pump onto the HEUI Pump
Illustration 4 g01458639
(1) HEUI pump (10) 239-2402 Seals
Install the three new 239-2402 Seals (10) on the back face of the HEUI pump (1). Refer to Illustration 4.
Illustration 5 g01470031
(2) Fuel transfer pump (11) 179-8128 Seal
Install a new 179-8128 Seal (11) on the fuel transfer pump (2). Refer to Illustration 5. Use 1U-6396 O-Ring Assembly Compound in order to hold the seal in place during assembly. Ensure that the seal is completely seated.
Illustration 6 g01132969
Do not remove the temporary bolt. Position the fuel transfer pump on the HEUI pump. Be sure to properly align the drive tang on the fuel transfer pump with the drive slot on the HEUI pump.Note: Align the drive tang of the fuel transfer pump so that the flat end is vertical. Refer to Illustration 5. Align the drive slot in the HEUI pump to a similar vertical orientation by using a flat head screwdriver. Refer to Illustration 6.Note: Once the fuel transfer pump has been placed onto the HEUI pump, ensure that the face of the fuel transfer pump is flush with the face of the HEUI pump. If the pump faces are not flush, verify the alignment of the drive tang.
Illustration 7 g01132938
(1) HEUI pump (2) Fuel transfer pump (4) Drive gear (5) 227-5904 O-Ring Seal (6) Tie Bolt (7) Bolts for the fuel transfer pump (8) Tie Bolts (9) Location for temporary bolt (12) 185-3241 O-Ring Seal
Install the three mounting bolts (7) for the fuel transfer pump (2).