101603-2612 ZEXEL F 01G 09U 045 BOSCH INJECTION-PUMP ASSEMBLY f01g09u045 1016032612 220401432a

1. Turn the engine counterclockwise (as seen from the flywheel end of the engine) with Tool (A) until the No. 1 piston is at top center (TC) on the compression stroke. Install the timing bolt. Install 6V-2112 Timing Pin through the hole in the injection pump housing. See the topic "Finding Top Center Compression Position for NO. 1 Piston" in SENR6577 Testing & Adjusting. Tool (B), 6V-2112 Timing Pin, replaces 6V-6019 Timing Pin. 2. Remove two bolts (1).3. Remove eleven bolts (2) and cover (3). 4. Remove four bolts (5), retainer (6) and automatic timing advance (4).Install Automatic Timing Advance
1. Install automatic timing advance (4). Install retainer (6) and four bolts (5).2. Tighten the bolts (5) with fingers until there is a small amount of friction (slight drag) between the retainer and automatic timing advance (4). This friction will hold the unit against the timing gears. This prevents play (backlash) when gears are turned to the correct position.3. Remove the timing bolt. Turn the flywheel until the timing pin will go into the groove in the injection pump camshaft.4. With the timing pin installed, turn the flywheel clockwise (opposite the direction of engine rotation) a minimum of 30 degrees. The reason for this step is to be sure the play is removed from the timing gears when the engine is put on top center (TC).5. Turn the flywheel in the direction of engine rotation until the No. 1 piston of the engine is on top center compression stroke. Then turn the timing bolt into the threaded hole in the flywheel.6. Tighten bolts (5) to 25 N m (20 lb ft). Then remove the timing pin from the injection pump housing.7. Tighten bolts (5) to 135 7 N m (100 5 lb ft). Then remove the timing bolt from the flywheel.8. Turn the crankshaft two complete revolutions and check the timing again to see that timing pin will go into the groove in the injection pump camshaft with bolt in flywheel.9. If timing is not correct, do the procedure of Steps 1 through 7 again. If the timing is correct, be sure to remove the timing pin and the timing bolt. 5. Install eleven bolts (2) and cover (3).6. Install two bolts (1). Disassemble Automatic Timing Advance
Start By:a. remove automatic timing advance 1. Remove flange assembly (1). 2. Remove two springs (2) and two weights (3) from drive gear assembly (4). 3. Remove two slides (5) from pistons (6).4. Separate drive gear assembly (4) from advance sleeve (7).Assemble Automatic Timing Advance
1. Put weights (3) in position in flange assembly (1) as shown.2. Install springs (2) in flange assembly (1). 4. Use 1P-008 General Purpose Lubricant to hold slides (5) in position on drive gear assembly (4). Install slides (5) on pistons (6).5. Install advance sleeve (7) to drive gear assembly (4). 6. Install drive gear assembly (4) on flange assembly (1). Make sure slides (5) fit in grooves of the weights.End By:a. install automatic timing advance