107691-3254 ZEXEL 9 400 612 183 BOSCH INJECTION-PUMP ASSEMBLY 9400612183 1076913254 220401220e

Crankshaft Gear Removal
Remove the gear using an 8B7548 Push Puller, 8B7551 Bearing Pulling Attachment, 8B7561 Step Plate, and 8H684 Ratchet Box Wrench.
PULLING CRANKSHAFT GEARThe 1P820 Hydraulic Puller Group can also be used to pull gear from crankshaft. Tools required are 1P820 Hydraulic Puller Group, 8B7551 Bearing Pulling Attachment, 8B7549 Puller legs (two), 8B7561 Step Plate, 3H465 Plate (four), 1B4207 Nut (two), and 9S5800 Pump Group.
USING HYDRAULIC PULLERCrankshaft Gear Installation
1. Install the key in keyway of crankshaft. Remove all burrs from key and keyway inside of crankshaft gear.2. Heat gear to 500° F. (260° C) maximum.3. Install gear on crankshaft with timing mark on gear facing front of crankshaft.Crankshaft Wear Sleeve Removal
REMOVING WEAR SLEEVEUse the 8S7164 Wear Sleeve Puller Group to remove the wear sleeve.Crankshaft Wear Sleeve Installation
WEAR SLEEVE INSTALLATION TOOLS
1. 5P290 Pilot. 2. 5P286 Ring. 3. 9S8858 Nut. 4. 1P5515 Bolts. 5. 9S8864 Pusher Plate.To install the wear sleeve, use the following procedure:1. Install 5P290 Pilot (1) on the end of the crankshaft. Install 1P5515 Bolts (4) and tighten just enough to hold pilot (1) yet allow some side movement. Put the wear sleeve on pilot (1) with the chamfer toward the rear of the engine. Push the wear sleeve on the crankshaft to put pilot (1) in the center, then tighten bolts (4).2. Put 5P286 Ring (2) on 9S8864 Pusher Plate (5) and place this assembly on the stud of pilot (1). Install 9S8858 Nut (3) and tighten nut to push wear sleeve on to the crankshaft.Crankshaft Rear Oil Seal Removal
Use the 1P3075 Puller Group to remove the crankshaft rear seal.
REMOVING REAR OIL SEAL (Typical Example)Crankshaft Rear Oil Seal Installation
REAR OIL SEAL INSTALLATION TOOLS
1. 5P290 Pilot. 2. 1P5515 Bolts. 3. 5P285 Ring. 4. 9S8858 Nut. 5. 5P288 Ring. 6. 9S8864 Pusher Plate.To install the crankshaft rear oil seal, use the following procedure:1. Install 5P290 Pilot (1) on the crankshaft with 1P5515 Bolts (2). Install 5P288 Ring (5) on pilot (1).2. Put 7F2770 Cement on the outer diameter of the seal metal shell. Put engine oil on the lip of the seal. Install the seal on the pilot with the lip of the seal toward the front of the engine.3. Install 9S8864 Pusher Plate (6) and 5P285 Ring (3) over pilot (1). Install 9S8858 Nut (4). Tighten nut (4) until ring (5) makes contact with the flywheel housing. To prevent possible oil leakage, install a new wear sleeve each time the rear oil seal is replaced.Crankshaft Front Oil Seal (1100, 3100, and 3208 Engines 79V1-79V1407)
The crankshaft front oil seal can be removed with the timing gear cover on or off the engine. To install the seal to the proper depth, the timing gear cover must be on the engine.A new timing gear cover permits the crankshaft front oil seal to be installed to two depths.Use the 9S6030 Installation Group which includes the 8S2276 Installer and 9S6012 Spacer to install the seal. To install seal to the original depth, use only the 8S2276 Installer. To obtain an additional wear