101049-4040 ZEXEL 9 410 613 466 BOSCH FUEL-INJECTION PUMP 9410613466 1010494040

Timing Gear Cover
Refer to SERVICE GUIDE for Preliminary Information.Two 3/8" NC Forcing Screws.
TIMING GEAR COVER1 Loosen bolt (2). Use two 3/8" NC forcing screws to remove pulley hub (1).2 At installation, tighten bolt to 230 20 lb. ft. (31,8 2,8 m.kg), tap bolt head with a hammer, and again tighten bolt to 230 20 lb. ft. (31,8 2,8 m. kg).3 Heat a new bushing in 250°F. (121°C.) oil for two hours before installation.4 Shim between trunnion hub and support halves to obtain a fit of .002 in. (0,05 mm) loose-to-.003 in. (0,07 mm) tight.5 Trim gasket flush with bottom face of cylinder block. Gaskets will leak if not cut square and flush with oil pan face.Timing Gears
Refer to SERVICE GUIDE for Preliminary Information.8S5132 Puller Plate,8S5133 Expansion Plug,8S6470 Pressure Screw,8B7561 Step Plate,Two 3/8" NF bolts.
Do not rotate the crankshaft with camshaft gear removed.
1 Use an 8S5132 Puller Plate, 8S5133 Expansion Plug, 8B7561 Step Plate, two 3/8" NF bolts and an 8S6470 Pressure Screw to remove gear. At installation, refer to topic FUEL INJECTION PUMP CAMSHAFT TIMING - FUEL SYSTEM - TESTING AND ADJUSTING.2 Fuel transfer pump must be removed before removing shaft. At installation, accessory drive shaft must be timed to crankshaft. Refer to FUEL INJECTION PUMP CAMSHAFT TIMING - FUEL SYSTEM - TESTING AND ADJUSTING.3 Trim gasket flush with bottom face of cylinder block. Gasket will leak if not cut square and flush with oil pan face.4, 6 Bearing must be centered in gear hub.5 Install washer with concave side toward gear (1).7 Align letter "C" on camshaft gear with letter "C" on crankshaft gear.8 Camshaft front bearing must be recessed .06 in. (1,52 mm) from front face of bore, oil hole in bearing must align with oil hole in cylinder block, and joint in bearing must face cylinder block centerline. Intermediate bearings must be flush with front face of bearing bore. Rear bearing must be recessed .06 in. (1,52 mm) from rear face of bore.Flywheel And Flywheel Housing
Refer to SERVICE GUIDE for Preliminary Information.FT125 Pilot and FT638 Sleeve (Fabricated Tools),5H1504 Washer,2J3506 Nut. 1, 2 Align mark on flywheel with mark on crankshaft.3 Heat ring gear. Do not exceed 600°F. (315°C.). Install with chamfered portion of ring gear teeth toward starter pinion when flywheel is installed.4 Use FT125 Pilot, FT638 Sleeve, 5H1504 Washer and a 2J3506 Nut to install seal.5 Trim gasket flush with bottom face of cylinder block. Gasket will leak if not cut square and flush with oil pan face.
This is an example of installing the crankshaft rear seal. A-FT638 Sleeve. B-2J3506 Nut. C-5H1504 Washer. D-FT125 Pilot. Secure pilot to crankshaft with three 5/8"-18 NF bolts, 2 in. (50,8 mm) long. Grind bolt head as necessary to provide seal clearance.