106671-0643 ZEXEL 9 400 616 671 BOSCH INJECTION-PUMP ASSEMBLY 9400616671 1066710643 1671396801

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). Put identification on each piston as to its location for correct installation and alignment. 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.
5. Do Steps 1 through 4 for the remainder of the pistons.Install Pistons
1. Put clean engine oil on the piston rings, connecting rod bearings and cylinder liner. 2. Install piston into cylinder liner with tool (A). Push piston and rings through tool (A) with a hammer handle.3. Make a check of the connecting rod bearing clearance. See REMOVE AND INSTALL CONNECTING ROD BEARINGS. 4. Put clean engine oil on connecting rod cap and bearing. Install the cap (1) on the connecting rod. Tighten nuts to a torque of 50 5 lb. ft. (70 7 N m) plus 180°.5. Do Steps 1 through 4 for the remainder of the pistons.
As caps are installed, make sure that number identification on cap is on same side as number identification on rod.
end by: a) install cylinder head and spacer plateb) install oil pumpDisassemble Pistons
start by: a) remove pistons 1. Remove the retaining rings (2) for the piston pin.2. Remove piston pin (1) and remove piston from the connecting rod.3. Remove the piston rings using ring expander (A).Assemble Pistons
1. Use ring expander (A) to install the piston rings. The two compression rings have marks "UP-1" and "UP-2". The rings must be installed with the marks toward the top of the piston with "UP-1" being the top ring. Put the ring gaps in place 120° from each other.2. Put clean oil on the piston pin. Put the piston in place on the connecting rod. Install the piston pin and retaining rings. On some engines there can be a "V" mark (2) on the piston. This mark must be on the same side as the location number (1) on the connecting rod.end by: a) install pistons