140262-0501 ZEXEL 9 411 619 616 BOSCH PLATE 9411619616 1402620501 62156120020

Firing order (injection sequence) ... 1, 5, 3, 6, 2, 4Injection timing before TC (top center) ... 12° 1°Injection timing before TC (top center) [aftercooled] ... 8° 30' 1°Torque for bolt in hole for timing pin ... 108 36 lb. in.(12.2 4.1 N m)Torque for bolts that hold governor weight carrier to camshaft ... 90 10 lb. in.(10.2 1.1 N m)(1) Diameter of rear bearing surface (journal) of the camshaft (new) ... 2.3720 .0005 in.(60.249 0.013 mm) Bore in the rear bearing for the camshaft (new) ... 2.3750 .0005 in.(60.325 0.013 mm)Maximum permissible clearance between the bearing and the camshaft bearing surface (journal) (worn) ... .006 in.(0.15 mm)(2) Diameter of sleeve control shaft (new) ... .3530 .0003 in.(8.966 0.008 mm) Bore in the housing for the fuel control shaft (new) ... .3543 .0005 in.(8.999 0.013 mm)Maximum permissible clearance between the bore in the housing and the sleeve control shaft (worn) ... .003 in.(0.08 mm)(3) End play for camshaft with sleeve installed (new) ... .023 .018 in.(0.58 0.46 mm) When installing sleeve on end of camshaft, support the camshaft to prevent damage to parts inside of injection pump and governor housing.(4) Diameter of front bearing surface (journal) of the camshaft (new) ... .9990 .0005 in.(25.375 0.013 mm) Bore in the front bearing for the camshaft (new) ... 1.0005 .0005 in.(25.413 0.013 mm)Maximum permissible clearance between the bearing and the camshaft bearing surface (journal) (worn) ... .003 in.(0.08 mm) Install spring washer with bent side towards the governor spring (5) as shown.(5) Governor Spring: (6) Bypass valve: If the spring keeps the pressure in the fuel injection pump housing above 25 psi (170 kPa) with the engine operating under full load, the spring is good.Pressure of fuel in housing for fuel injection pumps, (Full Load) ... 30 5 psi(205 35 kPa) Install guide pin (A) to depth (B) [.642 .003 in. (16.31 0.08 mm)]. Slot in guide pin (A) must be in area shown from center of lifter. (7) Torque for bushing ... 70 5 lb. ft.(95 7 N m)(8) 4N4318 Spring for injection pump: Length under test force ... 1.35 in.(34.3 mm)Test force ... 12.5 1.3 lb.(56 6 N)Free length after test ... 1.566 in.(39.78 mm)Outside diameter ... .728 in.(18.49 mm)(9) Torque for bolt holding sleeve on control shaft ... 24 2 lb. in.(2.8 0.2 N m) (10) Torque for the nuts that hold the fuel lines (Use 5P144 Fuel line Socket) ... 30 5 lb. ft.(40 7 N m)(11) Torque for the nuts that hold the nozzles ... 105 5 lb. ft.(142 7 N m)(12) Body.(13) Put 5P3931 Anti-Seize Compound on threads of glow plug and tighten to ... 120 24 lb. in.(13.6 2.8 N m)(14) Tighten nozzle finger tight on body.(15) Torque for precombustion chamber (put 5P3931 Anti-Seize Compound on threads)