101608-6320 ZEXEL 9 400 619 502 BOSCH INJECTION-PUMP ASSEMBLY 9400619502 1016086320

Fig. 33-Install Idler Gear ShaftPosition thrust washers behind shafts and press the shafts into the front plate, (Fig. 33).Install cap screw and washer in lower idler gear shaft from engine front plate side.
Fig. 34-Lower Gear Shaft TorqueLower idler gear shaft torque (Fig. 34) ... 95 lb-ft(129 N m) (13 kg-m)Position engine front plate on front of cylinder block and install attaching hardware.
Fig. 35-Front Plate Screw TorqueEngine front plate screw torque (Fig. 35) ... 20 to 25 lb-ft(27 to 34 N m) (2.8 to 3.5 kg-m)Install camshaft (Group 0402).
Fig. 36-JD-254 Timing ToolUsing JD-254 Timing Tool (1, Fig. 36), align timing mark on camshaft gear (2) with the timing tool.Install fuel injection pump (Group 0413).Install but do not tighten fuel injection pump drive gear nut.
Fig. 37-JD-254 Timing ToolUsing JD-254 Timing Tool (1, Fig. 37), align timing mark on fuel injection pump gear (2) with the timing tool.
Fig. 38-Upper Idler Gear and Thrust WasherPosition upper idler (1, Fig. 38) and thrust washers (2), without moving the camshaft gear or fuel injection pump gear, on the upper idler gear shaft. Make sure the roll pin in the idler shaft aligns with hole in thrust washer.Install, but do not tighten, upper idler gear cap screw.On four cylinder engines, install balancer shafts (Group 0415).
Fig. 39-JD254 Timing ToolUsing JD-254 Timing Tool (1, Fig. 39), align timing mark (2) on each balancer shaft gear with the timing tool.Install oil pump on front plate.
Fig. 40-Oil Pump Drive GearPosition oil pump drive gear on oil pump drive shaft without moving the left balancer shaft (Fig. 40).Install oil pump gear nut but do not tighten it.
Fig. 41-Lower Idler Gear and Thrust WasherPosition lower idler gear (1, Fig. 41) and thrust washers (2) on lower idler gear shaft without moving any of the other gears.Install, but do not tighten, lower idler gear cap screw.Using JD-254 Timing Tool check all of the timing marks to make sure they are properly aligned.
Fig. 42-Locking Timing Gear TrainPosition a screwdriver blade in the gear teeth between two gears (Fig. 42) to prevent them from rotating.Tighten the timing gear train attaching hardware using the following specifications:3-179D engine fuel injection pump gear torque ... 60 lb-ft(80 N m) (8.3 kg-m)
Fig. 43-Timing Gear Train Torque3-164D, 4-219D, 4-239D, 4-276D, 6-329D, and 6-359D engine fuel injection pump gear torque (1, Fig. 43) ... 45 lb-ft(61 N m) (6.2 kg-m)4-239T, 4-276T, 6-359T, 6-414D, and 6-414T engine fuel injection pump gear torque (1, Fig. 43) ... 150 lb-ft(203 N m) (20.7 kg-m)Upper idler gear torque (2) ... 65 lb-ft(88 N m) (9 kg-m)Lower idler gear torque (3) ... 95 lb-ft(129 N m) (13 kg-m)Oil pump gear torque (4) ... 35 to 45 lb-ft(47 to 61 N m) (5 to 6 kg-m)Install push rods and rocker arm assembly (Group 0402).Adjust valve clearance (Group 0402).Install rocker arm cover (Group 0402).Install timing gear cover (Group 0402).Install oil pan (Group 0407).Install oil pressure control valve (Group 0407).Install vibration damper (Group 0401).Install fan and fan belts (Group 0429).Install