101609-3181 ZEXEL 9 400 615 894 BOSCH INJECTION-PUMP ASSEMBLY 9400615894 1016093181 6221731320

(1) Bore in bearing of idler gear ... 28.600 0.048 mm (1.1260 .0019 in.) Diameter of shaft for the idler gear ... 28.512 0.013 mm (1.1225 .0005 in.)Clearance between bearing and shaft ... 0.028 to 0.150 mm (.0011 to .0059 in.)(2) Clearance between gear and body of pump ... 0.05 to 0.66 mm (.002 to .026 in.)(3) Diameter of shafts for pump ... 22.217 0.005 mm (.8747 .0002 in.) Bore in bearings for shafts (2P1785) ... 22.258 0.008 mm (.8763 .0003 in.)Bore in bearings for shafts (4W2448) ... 22.286 0.051 mm (.8774 .0020 in.)Clearance between shafts and bearings (2P1785) ... 0.028 to 0.053 mm (.0011 to .0021 in.)Clearance between shafts and bearings (4W2448) ... 0.025 to 0.127 mm (.0010 to .0050 in.)(4) Depth that bearings are installed in pump bodies ... 1.5 0.25 mm (.060 .010 in.)(5) Gear. Length of gears ... 50.808 0.025 mm (2.0003 .0010 in.) Depth of bore in pump body for gears ... 50.935 0.020 mm (2.0053 .0008 in.)Clearance between end of gears and pump body ... 0.081 to 0.173 mm (.0032 to .0068 in.)(6) Length of gears ... 38.070 0.025 mm (1.4988 .0010 in.) Depth of bore in pump body for gears ... 38.197 0.020 mm (1.5038 .0008 in.)Clearance between end of gears and pump body ... 0.081 to 0.173 mm (.0032 to .0068 in.)(7) Distance from the end of the idler shafts to gear faces ... 21.03 .127 mm (.828 .005 in.) Maximum temperature of gear when shrinking in place ... 398°C (750°F)(8) Distance from the end of the drive shaft to gear face ... 38.2 0.12 mm (1.505 .005 in.) Maximum temperature of gear when shrinking in place ... 398°C (750°F)(9) Torque for bolt holding drive gear to drive shaft ... 43 7 N m (32 5 lb ft) Install the bearings in the cover and body for the oil pump so the bearing junctions (joints) are in the position shown.(10) Distance dowel extends from body ... 6.0 0.5 mm (.24 .02 in.)(11) Shaft assembly. Distance shaft assembly extends from body ... 30.50 0.25 mm (1.200 .010 in.) Before running, lubricate pump with oil. Pump must rotate freely by hand.