106891-1540 ZEXEL 9 400 611 051 BOSCH INJECTION-PUMP ASSEMBLY 9400611051 1068911540 1156032040

Start By:a. remove camshaft 1. Remove eighteen bolts (1) and the washers that hold the front housing to the cylinder block. Remove the front housing. 2. Identify the location of the timing marks on the crankshaft drive gear and the camshaft idler gear assembly.3. Remove camshaft idler gear assembly (2). Remove the sleeve bearing from the camshaft idler gear.4. Remove the three bolts that hold idler shaft (3) to the cylinder block. Remove the idler shaft. The following steps are for the installation of the front housing and idler gear assembly. 5. Using Tool (A) and a press, install the sleeve bearing in the camshaft idler gear. Install the sleeve bearing until it is 0.40 0.25 mm (.016 .010 in) below the front face of the gear.6. Put idler shaft (3) in position on the cylinder block, and install the three bolts that hold it. Tighten the bolts to a torque of 70 15 N m (50 11 lb ft).7. Install camshaft idler gear assembly (2) on the idler shaft with the timing mark facing out. Align the timing marks on the camshaft idler gear with the hole in the crankshaft drive gear.8. Install the front housing as follows: a. Clean the joint face on the front housing with 8T9011 Component Cleaner.b. Apply 6V1541 Quick Cure Primer to the joint face. Allow the primer to dry for three to five minutes minimum.c. Apply 1U8846 Gasket Maker to the joint face. Spread the gasket maker uniformly. The front housing must be installed within ten minutes after application of the gasket maker.
Do not allow the 1U8846 Gasket Maker on the front housing to plug the main oil passage.
9. Put the front housing in position on the cylinder block, and install the eighteen washers and bolts (1) that hold it.End By:a. install camshaft