106692-4103 ZEXEL 9 400 617 824 BOSCH INJECTION-PUMP ASSEMBLY 9400617824 1066924103 6151711723

Disassembly
The following tools are needed: torque wrench, 16 millimeter socket or wrench, cotton swabs, rubbing alcohol, rubber gloves, small magnet, flashlight, plastic spray bottle and molykote or white lithium greaseThe following parts are supplied: two plugs for the outlet check valves, two outlet check valves, two springs and two ball studs
Ensure the proper cleanliness of hands and all parts before you begin the service procedure.
Check the engine serial number in order to ensure that the engine is correct for the service letter.
Steam clean the area that surrounds the plug for the outlet check valve or clean the area around the plug for the outlet check valve by flushing with rubbing alcohol.
The area must be cleaned with a towel that is soaked with alcohol in order to remove any other debris.
Inspect the area that is surrounding the plug for the outlet check valve in order to ensure that no debris is present.
Illustration 1 g01618509
Using a clean 16 millimeter socket or a wrench remove the plug for the outlet check valve.
Carefully remove the plug from the pump head. The spring is removed with the plug.
If the outlet check valve remains in the head, remove the check valve with the clean magnet.
Clean the threads and the area around the plug.Note: Soak the cotton swab with alcohol and insert the cotton swab into the threaded area. Use a counterclockwise rotation to clean the threaded area. Clean the spot face around the plug bore with a cotton swab that is soaked in alcohol. Clean the spot face around the plug bore in a counterclockwise rotation.
Illustration 2 g01626597
(1) Sealing surface of the pump bore
Look inside the pump bore in order to ensure that no debris that includes the debris from the cotton swab is on the sealing surface.
Repeat until the cotton swab is free of debris.
Illustration 3 g01618506
Assembly
Once parts have been removed, clean hands and put on clean rubber gloves.
When the parts are being installed in the pump, flush all the new parts with alcohol in order to ensure that no debris is on the parts.
Use a clean finger to apply clean molykote or white lithium grease to the surface that is being sealed and threads of plug.
Illustration 4 g01624087
Use clean molykote or white lithium grease in order to install the ball stud on the end of the spring. Press the ball stud and the spring together.
Illustration 5 g01624092
Insert the subassembly of the ball stud and the spring into the plug for the outlet check valve, with the end with the ball stud in the plug.Note: Be careful not to scratch the sealing surface of the plug for the outlet check valve.
Illustration 6 g01626602
(2) Sealing surface of the plug for the outlet check valve
Illustration 7 g01624154
(3) Gauge Pin
Illustration 8 g01624824
(4) Location of the ring groove on the gauge pin on a properly assembled ball stud and spring assembly
The distance between the end of the spring and the sealing surface of the plug for the outlet check valve should be checked with a gauge pin. The ring groove must be above the top