101043-9230 ZEXEL 9 410 612 638 BOSCH FUEL-INJECTION PUMP 9410612638 1010439230 5156100750

start by:a) remove automatic timing advanceb) remove vibration damper and pulleyc) remove water pumpd) remove belt tightener idler pulleye) remove water temperature regulator (left cylinder head)1. Remove the tube assembly from the oil cooler elbow to the oil pan.2. Loosen the bolts that hold the oil pan to the cylinder block approximately 1/4" (6.4 mm). Remove the bolts that hold the oil pan to the timing gear cover.3. Fasten a hoist to the engine and lift it off tool (A). Weight of the engine is 3200 lb. (1452 kg). Make a separation of the oil pan from the cylinder block and timing gear cover. Do not damage the pan gasket.4. Put 1/4" (6.4 mm) pieces of bar stock between the pan and cylinder block at the positions the oil pan makes contact with tool (A). Lower the engine on tool (A).5. Remove the bolts from the belt tightener bracket. Remove the block and gasket. 6. Remove fumes disposal tube (1).7. Remove the bolts (4) that hold the timing gear cover to the cylinder block.8. Remove water bonnet (2).9. Remove timing gear cover (3).
Do not cause damage to the crankshaft front seal when the cover is removed.
10. Check the condition of the O-ring seal on the fuel injection pump housing.Install Timing Gear Cover
1. Put clean engine oil on the O-ring seal for the fuel injection pump housing, the crankshaft front seal and wear sleeve.2. Install tool (B) in the crankshaft front seal.3. Install a new gasket on the timing gear cover. Put timing gear cover (1) in position on the dowels in the cylinder block. Make sure it is against the cylinder block all around.4. Install the bolts that hold the cover in position. Remove tool (B) from the crankshaft front seal.5. Install the water bonnet, the fumes disposal tube and the block for the belt tightener bracket.6. Fasten a hoist to the engine and lift it off tool (A). Remove the bar stock from between the cylinder block and oil pan. Tighten the bolts that hold the oil pan to the cylinder block.7. Install the bolts that hold the oil pan to the timing gear cover. Put the engine back on tool (A).8. Install the tube assembly between the oil pan and oil cooler.end by:a) install water temperature regulator (left cylinder head)b) install belt tightener idler pulleyc) install water pumpd) install vibration damper and pulleye) install automatic timing advance