101402-9803 ZEXEL 9 400 613 435 BOSCH INJECTION-PUMP ASSEMBLY 9400613435 1014029803 12991651011

Start By:a. remove timing gear coverb. remove fuel injection pump housing and rack actuator package 1. Remove four bolts (2), plate (3) and idler gear (1). 2. If the camshaft is not going to be removed, use tooling (A) to remove camshaft gear (4).
Do not turn the crankshaft with the camshaft gear removed. Damage can be caused to the pistons and valves, or both.
3. Remove bolts (5) that hold timing gear plate (6) to the cylinder block.4. Remove timing gear plate (6). 5. Use tooling (B) to remove the bearing from the idler gear. The following steps are for the installation of the timing gears and plate.6. Install a new gasket on the timing gear plate.7. Put timing gear plate (6) in position on the cylinder block, and install the bolts that hold the timing gear plate to the cylinder block.8. Heat camshaft gear (4) to a maximum temperature of 315° C (600° F), and install it on the camshaft.9. Use tooling (B), and install the bearing in the idler gear. Set the gear on the front face, (face with timing marks). Drive the bearing from the rear face toward the front face of the gear. Install the bearing to a depth of 1.5 0.5 mm (.06 .02 in.) below the rear face of the idler gear.10. Install the idler gear, plate and bolts. Be sure No. 1 cylinder is at top center on the compression stroke. Install the idler gear so "V" mark (7) on the idler gear is in alignment with the "V" mark on the crankshaft gear. "K" marks (8) of the camshaft gear can be seen at the outer edges of the idler gear.End By:a. install fuel injection pump housing and rack actuator packageb. install timing gear cover