101606-6890 ZEXEL 9 400 615 543 BOSCH INJECTION-PUMP ASSEMBLY 9400615543 1016066890 me056854

2. Remove bolts (3) from cover (1). Remove bolt and washer (2) and remove tube and adapter (4). 3. Remove adapter (5) from tube (4). Remove four O-ring seals (6) from tube (4). 4. Remove four bolts (7), elbow (9) and two adapters (8). 5. Remove four bolts (11), elbow (12), two adapters (10) and pipe (13). 6. Remove twenty-four bolts (15). Remove aftercooler cover (14). 7. Remove aftercooler core (16) from aftercooler housing (17). 8. Remove O-ring seals (19) and gaskets (18) if necessary. The following steps are for the installation of the aftercooler core.9. Clean and inspect all parts. Make a replacement of the parts that are worn or damaged. Lubricate O-ring seals with clean oil at assembly.10. Install O-ring seals (19). Fasten gaskets (18) to both sides of the aftercooler core flange with 5H2471 Cement.11. Install aftercooler core (16) in the aftercooler housing with the end that has the identification "Jacket Water, Fresh Air" or "Treated Water, Fresh Air" toward the water inlet end of the aftercooler housing.12. Install cover (14) on aftercooler housing (17).
To prevent damage to the aftercooler core, tighten the bolts that hold the aftercooler core before tightening the bolts that hold the adapters.
13. Tighten the aftercooler core cover bolts to a torque of 25 7 N m (18 5 lb. ft.). Tighten the bolts again after the engine is operated to a torque of 25 7 N m (18 5 lb. ft.).14. Install the gaskets and adapters (10) on the aftercooler housing. 15. Put O-ring seals (20) on pipe (13) and install pipe (13) into elbow (21).16. Install elbow (12) on pipe (13). Put a gasket between the adapters and elbow (12). Install bolts (11).17. Install gaskets and adapters (8) on the aftercooler housing. Install a gasket and elbow (9). Install bolts (7).18. Install O-ring seals (6) on tube (4). Install adapter (5) on tube (4).19. Install the gasket, adapter and tube (4). Install washer and bolt (2). Install the gasket and cover (1). Tighten bolts (3) to 23 4 N m (17 3 lb. ft.).20. Fill the engine with oil to the correct level. See the Maintenance Manual.