Information injection-pump assembly
BOSCH
9 400 612 053
9400612053
ZEXEL
107492-1034
1074921034
Rating:
Service parts 107492-1034 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
9.
_
11.
Nozzle and Holder
8-97148-960-1
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
107492-1034
as INJECTION-PUMP ASSEMBLY
Cross reference number
Zexel num
Bosch num
Firm num
Name
Information:
Parts Location
Illustration 2 g01601433
(1) 308-4943 Diesel Particulate Filter Group (2) 235-3963 Clamp Assembly (3) 308-4945 Bracket Assembly (4) 8T-4183 Bolt (5) 5P-8245 Hard Washer (6) 241-9265 Muffler Clamp Installation Procedure
Diesel Particulate Filter Installation
Illustration 3 g01606937
Typical Example (11) Existing muffler assembly (12) Existing bracket assembly (13) Support Assembly (14) Muffler Clamp (15) Tube assembly (16) Engine lifting plate (17) Bolt (18) Hard washer (19) Bolt
Remove existing muffler assembly (11) and bracket assembly (12). Set aside the three 8T-4183 Bolts (17), the five 8T-4184 Bolts (19) and the eight 5P-1076 Hard Washers (18). These parts will be reused in Steps 2 and 3. Refer to Illustration 3.
Illustration 4 g01601354
(3) 308-4945 Bracket Assembly (17) Bolt (18) Hard washer
Install 308-4945 Bracket Assembly (3) onto support assembly (13) by reusing three bolts (17) and three hard washers (18) that were removed in Step 1. Refer to Illustrations 3 and 4.
Illustration 5 g01601373
(19) Bolt
Reuse five bolts (19) and five hard washers (18) removed in Step 1 to secure bracket assembly (3) to engine lifting plate (16). Refer to Illustrations 3 and 5.
Illustration 6 g01601413
(2) 235-3963 Clamp Assembly (Lower half) (4) 8T-4183 Bolt (5) 5P-8245 Hard Washer
Remove the two bolts, two hard washers, two lock washers, and two nuts from each 235-3963 Clamp Assembly (2). Keep these parts together with the upper half of clamp assembly (2). These parts will be reinstalled in Step 8.
Install the lower half of 235-3963 Clamp Assembly (2) by using two 8T-4183 Bolts (4) and two 5P-8245 Hard Washers (5). Loosely secure these bolts so that the clamp assembly is adjustable. Repeat for the other clamp assembly (2). Refer to Illustration 6.
Illustration 7 g01601473
(1) 308-4943 Diesel Particulate Filter Gp
Install 308-4943 Diesel Particulate Filter Group (1) onto the lower halves of clamp assemblies (2). The weight of the diesel particulate filter group is approximately 40 kg (88 lb). Make sure that the inlet tube (not shown) of the inlet module of the diesel particulate filter fits into tube assembly (15). Use a new 241-9265 Muffler Clamp (6) to secure the connection. Refer to Illustrations 3 and 7.
Illustration 8 g01601333
(2) 235-3963 Clamp Assembly (Upper half) (2a) Bolt (2b) Hard washer (2c) Lock washer (2d) Nut
Once you have properly installed the tube assembly, tighten both bolts (4) to secure the bottom half of clamp assembly (2). Repeat for the other clamp assembly (4). Install the upper half of clamp assembly (2) by using two bolts (2a) and two hard washers (2b) through the upper clamp assembly, and two lock washers (2c) and two nuts (2d) on the lower clamp assembly. Repeat for the other clamp assembly. Refer to Illustration 8.
Reconnect the drain lines.Exhaust Monitor Installation
Refer to Special Instruction, REHS5606, "Installation and Operation of the Exhaust Monitor Used in All Diesel Particulate Filter (DPF) Retrofit Emissions Applications" for information regarding the installation and the operation of the exhaust monitor.The exhaust
Illustration 2 g01601433
(1) 308-4943 Diesel Particulate Filter Group (2) 235-3963 Clamp Assembly (3) 308-4945 Bracket Assembly (4) 8T-4183 Bolt (5) 5P-8245 Hard Washer (6) 241-9265 Muffler Clamp Installation Procedure
Diesel Particulate Filter Installation
Illustration 3 g01606937
Typical Example (11) Existing muffler assembly (12) Existing bracket assembly (13) Support Assembly (14) Muffler Clamp (15) Tube assembly (16) Engine lifting plate (17) Bolt (18) Hard washer (19) Bolt
Remove existing muffler assembly (11) and bracket assembly (12). Set aside the three 8T-4183 Bolts (17), the five 8T-4184 Bolts (19) and the eight 5P-1076 Hard Washers (18). These parts will be reused in Steps 2 and 3. Refer to Illustration 3.
Illustration 4 g01601354
(3) 308-4945 Bracket Assembly (17) Bolt (18) Hard washer
Install 308-4945 Bracket Assembly (3) onto support assembly (13) by reusing three bolts (17) and three hard washers (18) that were removed in Step 1. Refer to Illustrations 3 and 4.
Illustration 5 g01601373
(19) Bolt
Reuse five bolts (19) and five hard washers (18) removed in Step 1 to secure bracket assembly (3) to engine lifting plate (16). Refer to Illustrations 3 and 5.
Illustration 6 g01601413
(2) 235-3963 Clamp Assembly (Lower half) (4) 8T-4183 Bolt (5) 5P-8245 Hard Washer
Remove the two bolts, two hard washers, two lock washers, and two nuts from each 235-3963 Clamp Assembly (2). Keep these parts together with the upper half of clamp assembly (2). These parts will be reinstalled in Step 8.
Install the lower half of 235-3963 Clamp Assembly (2) by using two 8T-4183 Bolts (4) and two 5P-8245 Hard Washers (5). Loosely secure these bolts so that the clamp assembly is adjustable. Repeat for the other clamp assembly (2). Refer to Illustration 6.
Illustration 7 g01601473
(1) 308-4943 Diesel Particulate Filter Gp
Install 308-4943 Diesel Particulate Filter Group (1) onto the lower halves of clamp assemblies (2). The weight of the diesel particulate filter group is approximately 40 kg (88 lb). Make sure that the inlet tube (not shown) of the inlet module of the diesel particulate filter fits into tube assembly (15). Use a new 241-9265 Muffler Clamp (6) to secure the connection. Refer to Illustrations 3 and 7.
Illustration 8 g01601333
(2) 235-3963 Clamp Assembly (Upper half) (2a) Bolt (2b) Hard washer (2c) Lock washer (2d) Nut
Once you have properly installed the tube assembly, tighten both bolts (4) to secure the bottom half of clamp assembly (2). Repeat for the other clamp assembly (4). Install the upper half of clamp assembly (2) by using two bolts (2a) and two hard washers (2b) through the upper clamp assembly, and two lock washers (2c) and two nuts (2d) on the lower clamp assembly. Repeat for the other clamp assembly. Refer to Illustration 8.
Reconnect the drain lines.Exhaust Monitor Installation
Refer to Special Instruction, REHS5606, "Installation and Operation of the Exhaust Monitor Used in All Diesel Particulate Filter (DPF) Retrofit Emissions Applications" for information regarding the installation and the operation of the exhaust monitor.The exhaust