101603-2402 ZEXEL 9 400 615 052 BOSCH INJECTION-PUMP ASSEMBLY 9400615052 1016032402 220009641a

Start By:a. remove timing gear coverb. remove flywheel housing*c. remove engine oil cooler**d. remove oil filter base***Put the engine in time before the flywheel housing is removed. See the topic, "Finding Top Center Compression Position For No. 1 Piston" in Testing & Adjusting Manual SENR6471.**These operations must be done to install Tool (A) on the engine.
Typical Example1. Fasten the engine on Tool (A). The weight of the engine is 1362 kg (3000 lb).2. Remove the bolts and nuts that hold air cleaner group (1), pipe assembly (3), bracket assembly (4) and lifting plate (5) as a unit to the engine. Fasten a hoist to the unit and remove it from the engine. The weight of the unit is approximately 39 kg (85 lb).3. Remove tube assembly (2) from the engine.
Typical Example4. Install the two bolts to hold the primary fuel filter bracket (6) in place while the engine is turned with Tool (A). 5. Turn the engine to the position shown with Tool (A). Remove rod bearing caps (8) from the ends of the connecting rods. Push the connecting rods away from the crankshaft.6. Remove the bolts and remove main bearing caps (7) from the crankshaft. 7. Remove thrust plates (9) from the center main bearing journal. 8. Fasten a hoist to crankshaft (10) with tooling (B). Remove crankshaft (10) from the engine block. The weight of the crankshaft is 159 kg (350 lb). 9. Use Tool (C) to remove outer gear (2) from the end of the crankshaft.10. Use a hammer and chisel to remove the spacer from the crankshaft. 11. Use Tool (D) to remove the gear alignment dowel from the crankshaft.12. Use Tool (C) to remove inner gear (11) from the end of the crankshaft. If new main bearings are not to be installed, put identification on the old main bearings as to their location in the cylinder block and to which main bearings caps they belong.13. Remove main bearings (13) from the cylinder block and the main bearing caps.Install Crankshaft
1. If the dowel was removed from the flywheel end of the crankshaft, install it in the crankshaft to a maximum dimension of 6.4 mm (.25 in).2. Heat the crankshaft gears to a maximum temperature of 205° C (400° F).3. The centerline of inner gear key must be in alignment with the centerline of the dowel hole within 0.51 mm (.020 in). Install crankshaft inner gear (14) on the crankshaft.4. Install the spacer on the crankshaft.5. Install the dowel in the crankshaft. The dowel must be extended no more than 4.1 0.5 mm (.16 .02 in) from the surface of the crankshaft. The dowel in the crankshaft must be in alignment with the notch in crankshaft gear (15).6. Make sure the "V" mark on the crankshaft gear is toward the outside, and install crankshaft gear (15). 7. Thoroughly clean the cylinder block and main bearing caps.
Make sure the upper and lower halves of the main bearings are installed so the bearing tabs fit