Information fuel-injection pump
BOSCH
9 461 616 062
9461616062
ZEXEL
104640-3991
1046403991
Rating:
Include in #2:
104740-3991
as FUEL INJECTION PUMP
Cross reference number
Zexel num
Bosch num
Firm num
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Information:
Camshaft
When reconditioning an engine, check the diameter of the camshaft bearing journals and the camshaft lobe height.Camshaft bearing journals have a diameter of 2.5000 .0005 in. (63.500 0.013) and the minimum diameter worn is 2.4970 in. (63.424 mm).To measure height (B) of camshaft lobes, use the following procedures: 1. Measure base circle (C) of one exhaust and one intake lobe. Make a record of each dimension.2. Add lobe lift dimension (A) to each base circle measurement. The lobe lift dimension (A) is .3071 in. (7.800 mm) for the exhaust lobe and .3077 in. (7.816 mm) for the intake lobe.3. The minimum height of lobe (B) is .025 in. (0.64 mm) less than the dimension found in Step 2.Example of finding the height of a lobe:Base circle (C) ... 1.8200 in.(46.228 mm)Add lobe lift (A) ... .3077 in.(7.816 mm)Lobe height (B) ... 2.1277 in.(54.044 mm)Maximum wear of lobe ... .025 in.(0.64 mm)Minimum height of lobe ... 2.1027 in.(53.409 mm)
CAMSHAFT LOBE
A. Lobe lift. B. Lobe height. C. Base circle.With camshaft installed in the cylinder block, check end play. End play with new components should be .007 .003 in. (0.18 0.08 mm). The maximum permissible end play is .020 in. (0.51 mm).Camshaft Followers
Use an 8S2293 Magnet to remove the cam followers.
REMOVING CAM FOLLOWERSCam followers establish a wear pattern with the camshaft lobes. Identify and reinstall the followers in the same location from which they were removed. Dishing or circular wear pattern is allowed on the cam follower face, providing the wear face keeps a polished appearance. Replace the follower if the wear face is rough or shows signs of scuffing. A new follower can be used with an old camshaft, providing the lobe is in good condition. Put engine oil on the cam followers and the camshaft lobes before installing the cam followers. Use new cam followers with a new camshaft.Camshaft Gears
1100 and 3100 Engines With Fuel Pump Camshaft Mounted Timing Advance
1. Use a 1P2320 Puller to remove the camshaft small outer gear.
PULLING SMALL GEAR (Typical Example)2. Remove the spacer immediately behind the gear.3. Use a 1P2321 Puller to remove the camshaft large inner gear.
PULLING LARGE GEAR (Typical Example)4. To install, heat both gears to a maximum temperature of 600° F. (315° C).5. Align keyway of large gear with key in camshaft. Install large inner gear on camshaft with timing mark on gear aligned with timing mark on crankshaft gear.6. Install the spacer and small outer gear.
Do not drive gears onto camshaft. Serious damage can result to camshaft or camshaft thrust pin.
Engines With Engine Camshaft Mounted Timing Advance
1. Remove screw (1) and washer (2) from end of camshaft.
REMOVING TIMING ADVANCE RETAINING SCREW
1. Screw. 2. Washer.2. Remove timing advance unit from the camshaft.3. Install puller (A), with spacer (C) over the shaft in the camshaft and spacer (B) on spacer (C) as shown and remove the gear from the camshaft.
REMOVING GEAR (Typical Example)
A. 1P2321 Puller. B. 8S5579 Spacer. C. 9S9155 Spacer.To install the gear use the following procedure:1.
When reconditioning an engine, check the diameter of the camshaft bearing journals and the camshaft lobe height.Camshaft bearing journals have a diameter of 2.5000 .0005 in. (63.500 0.013) and the minimum diameter worn is 2.4970 in. (63.424 mm).To measure height (B) of camshaft lobes, use the following procedures: 1. Measure base circle (C) of one exhaust and one intake lobe. Make a record of each dimension.2. Add lobe lift dimension (A) to each base circle measurement. The lobe lift dimension (A) is .3071 in. (7.800 mm) for the exhaust lobe and .3077 in. (7.816 mm) for the intake lobe.3. The minimum height of lobe (B) is .025 in. (0.64 mm) less than the dimension found in Step 2.Example of finding the height of a lobe:Base circle (C) ... 1.8200 in.(46.228 mm)Add lobe lift (A) ... .3077 in.(7.816 mm)Lobe height (B) ... 2.1277 in.(54.044 mm)Maximum wear of lobe ... .025 in.(0.64 mm)Minimum height of lobe ... 2.1027 in.(53.409 mm)
CAMSHAFT LOBE
A. Lobe lift. B. Lobe height. C. Base circle.With camshaft installed in the cylinder block, check end play. End play with new components should be .007 .003 in. (0.18 0.08 mm). The maximum permissible end play is .020 in. (0.51 mm).Camshaft Followers
Use an 8S2293 Magnet to remove the cam followers.
REMOVING CAM FOLLOWERSCam followers establish a wear pattern with the camshaft lobes. Identify and reinstall the followers in the same location from which they were removed. Dishing or circular wear pattern is allowed on the cam follower face, providing the wear face keeps a polished appearance. Replace the follower if the wear face is rough or shows signs of scuffing. A new follower can be used with an old camshaft, providing the lobe is in good condition. Put engine oil on the cam followers and the camshaft lobes before installing the cam followers. Use new cam followers with a new camshaft.Camshaft Gears
1100 and 3100 Engines With Fuel Pump Camshaft Mounted Timing Advance
1. Use a 1P2320 Puller to remove the camshaft small outer gear.
PULLING SMALL GEAR (Typical Example)2. Remove the spacer immediately behind the gear.3. Use a 1P2321 Puller to remove the camshaft large inner gear.
PULLING LARGE GEAR (Typical Example)4. To install, heat both gears to a maximum temperature of 600° F. (315° C).5. Align keyway of large gear with key in camshaft. Install large inner gear on camshaft with timing mark on gear aligned with timing mark on crankshaft gear.6. Install the spacer and small outer gear.
Do not drive gears onto camshaft. Serious damage can result to camshaft or camshaft thrust pin.
Engines With Engine Camshaft Mounted Timing Advance
1. Remove screw (1) and washer (2) from end of camshaft.
REMOVING TIMING ADVANCE RETAINING SCREW
1. Screw. 2. Washer.2. Remove timing advance unit from the camshaft.3. Install puller (A), with spacer (C) over the shaft in the camshaft and spacer (B) on spacer (C) as shown and remove the gear from the camshaft.
REMOVING GEAR (Typical Example)
A. 1P2321 Puller. B. 8S5579 Spacer. C. 9S9155 Spacer.To install the gear use the following procedure:1.