106682-4560 ZEXEL INJECTION-PUMP ASSEMBLY Cross 1066824560

Do not heat the gear with a torch. Do not heat the gear to a temperature of more than 315°C (600°F). Heating the gear with a torch or to a temperature of more than 315°C (600°F) may cause the two drive dowels for the automatic timing advance to loosen and come out of the gear.
2. Align slot in gear hub with the pin in the camshaft. Install the gear on the camshaft with timing mark on gear aligned with timing mark on crankshaft gear. Be sure the gear is completely seated against the shoulder of the camshaft.
Do not drive the gear on the camshaft.
3. Align holes in weights with dowels in gear and install the automatic timing advance.4. Align pin (3) in washer with hole (4) in camshaft and install washer (2).5. Install screw (1) and tighten to 7.9 0.6 N m (70 5 lb in). Stake screw in two places.
Installing Washer
(2) Washer. (3) Pin. (4) Hole.
Stake screw (1) carefully. Heavy blows on washer or screw can force the shaft extension too far into the camshaft and eliminate all end clearance.
6. After screw (1) is staked, the gear and weight assembly requires 0.08 to 0.94 mm (.003 to .037 in) end clearance to prevent binding against the washer, camshaft end or camshaft gear.
Staking Screw
(1) Screw.Camshaft Bearings Removal and Installation
Remove camshaft bearings using the 1P5544 Washer (1) and 0S0509 Bolts (2), from the 1P5545 Adapter Group, in conjunction with the 8S2241 Camshaft Bearing Removal and Installation Group, and the 8H0684 Ratchet Box Wrench.
Installing Washer
(1) 1P5544 Washer. (2) 0S0509 Bolt.With removal tools installed on cylinder block, remove bearings.
Removing Camshaft BearingsUse the 1P5545 Adapter Group in conjunction with the 8S2241 Camshaft Bearing Removal and Installation Group, and the 8S0684 Ratchet Box Wrench to install camshaft bearing.
Installing Camshaft BearingsThe 1P5545 Adapter Group pilots in the camshaft bearing bore and also pilots the bearing into the bore. This insures bearing alignment. Install bearings from chamfered side of the bore and align oil hole in bearings with oil holes in cylinder block.To install the camshaft front bearing, it is necessary to machine a notch in the 8S8289 Tube (3) for clearance of the boss that projects above the camshaft bearing bore. Machine the notch 38.1 mm (1.50 in) wide, 9.5 mm (.37 in) deep, with a 3.2 mm (.13 in) radius or chamfer in the corners and on the edges.
Notch In Tube
(3) 8S8289 Tube. (4) 8S8288 Cone. (5) Notch.Invert the 8S8288 Cone (4) and install it in the 8S8289 Tube (3) for installation of the camshaft front bearing.
Installing Camshaft Front Bearing
(3) 8S8289 Tube. (4) 8S8288 Cone.Engine Test Procedure
Lubrication For A Rebuilt Engine
It is very important for a rebuilt engine to have "adequate" (needed) lubrication during the first seconds of operation. A "dry start" (without needed lubrication) on a rebuilt engine can cause bearing damage.When an engine is rebuilt with new parts, oil is put on each part as it is installed. This is generally enough lubrication for engine start-up. However, this lubrication