Note. The timing case must be removed for the following operations.
1. Duplex Injection Pump Sprocket, Remove and Install
2. Duplex Timing Chain, Remove and Install
3. Guide Rail, Duplex Timing Chain, Remove and Install
4. Crankshaft Sprocket, Remove and Install
5. Timing Chain Tension Rails, Remove and Install
6. Gasket, Timing Case, Replace
7. Oil Pump, Remove and Install (Not Shown in Illustration F 9839)
Remove
Remove engine – see operation "Engine, Remove and Install".
Disconnect engine damping block bracket from cylinder block and mount engine with Adapters KM-412-8-1 and KM-412-16 on Mounting Trestle KM-412.
Remove upper part of oil pan – see operation "Oil Pan – Upper Part, Remove and Install".
Remove cylinder head – see operation "Cylinder Head, Remove and Install".
Disconnect cable connections from alternator.
Remove fastening bolt (1) and remove alternator.
Caution
Remove Crankshaft Retaining Pin KM-929 (2).
Remove
Loosen fastening bolt for torsional vibration damper (1) (do not remove) – counterhold with KM-977-1 (2) in conjunction with KM-956.
Install
Reinsert Crankshaft Lock Pin KM-929 (3) to stop in aperture for crankshaft pulse pick-up.
Inspect
Marks (4) must align in this position.
Remove
Remove torsional vibration damper.
Remove
Remove duplex chain tensioner (1).
Detach timing case (2) from cylinder block – note different bolt lengths.
Lever seal ring (3) from timing case – ensure that sealing surfaces are not damaged.
Remove
Remove fastening bolts (1) and remove simplex fuel injection pump sprocket with simplex timing chain.
Remove guide rail for duplex timing chain (2) from cylinder block.
Remove timing chain tension rails (3) from cylinder block.
Remove crankshaft sprocket with duplex timing chain and duplex fuel injection pump sprocket.
Remove timing case gasket.
Clean
Clean sealing surfaces and remove gasket remnants.
Inspect
Check all parts and replace if necessary.
Install
Insert new gasket (1) in cylinder block.
Adjust
Recess in fuel injection pump flange (2) must align with lock bore (3) in fuel injection pump.
Inspect
Check condition of spring washer.
Install
Place crankshaft sprocket (6) with duplex timing chain (5) and duplex fuel injection pump sprocket (3) on crankshaft or fuel injection pump flange.
Caution
Ensure that recess is positioned in fuel injection pump flange and that retaining bore (1) is centrally positioned in oblong hole (2) on duplex fuel injection pump gear – tension side (I) must be taut.
Install
Attach guide rail of duplex timing chain (4) to cylinder block – tightening torque 8 Nm / 6 lbf. ft.
Attach timing chain tension rail (7) to cylinder block – tightening torque 20 Nm / 15 lbf. ft.
Install
Place simplex injection pump sprocket on flange of injection pump and tighten new fastening bolts by hand.
Place simplex timing chain on simplex fuel injection pump sprocket and hang over timing chain tension rail (simplex).
Caution
Arrow (1) on simplex fuel injection pump sprocket must align with recess in fuel injection pump flange and lock bore (2) in fuel injection pump.
Injection Pump Lock Pin KM-927 (3) must be able to be removed and installed under suction.
Install
When replacing timing case: transfer attaching parts.
Attach timing case to cylinder block – tighten fastening bolts uniformly – 20 Nm / 15 lbf. ft.
Lightly coat sealing lip of the new seal ring with silicon grease (white).
Place seal ring on Protective Sleeve KM-935-1 (1) and apply to timing case without tilting.
Place seal ring on protective sleeve with KM-935-2 (2) and press in seal ring until it is seated flush in timing case – use fastening bolt of torsional vibration damper.
Caution
Remove Crankshaft Retaining Pin KM-929 (1) and Fuel Injection Pump Retaining Pin KM-927.
Install
Install upper part of oil pan – see operation "Oil Pan – Upper Part, Remove and Install".
Caution
Align upper part of oil pan with straight edge on cylinder block – note tightening sequence and tightening torques.
Install
Connect torsional vibration damper (2) with new bolt to crankshaft – counterhold with KM-977-1 (3) in conjunction with KM-956 – tightening torque 150 Nm / 111 lbf. ft. + 45° + 15°.
Install
Reinsert Crankshaft Retaining Pin KM-929 to stop in aperture for crankshaft pulse pick-up.
Inspect
In this position, marks (1) must align with one another.
Inspect
Arrow (1) on simplex fuel injection pump sprocket must align with recess in fuel injection pump flange and lock bore (2) in fuel injection pump.
Install
Insert Injection Pump Lock Pin KM-927 (3) in lock bore of fuel injection pump.
Install
Insert duplex chain tensioner (5) in timing case – closed side of chain tensioner must face tension rail. Install closure bolt (3) with new seal ring (4) – tightening torque 60 Nm / 44 lbf. ft.
Caution
A distinction must be made between designs with a release pin (2) and without a release pin.
In the design with a release pin, the chain tensioner must be relieved of tension via the release pin after assembly!
Inspect
Press in the release pin with a hammer shaft until a click is heard.
It must be possible to push in release bolt up to stop with thumb and for it to slide back to its original position automatically – the release bolt can no longer be pushed in once the oil pressure has built up.
Remove Injection Pump Engagement Pin KM-927. Tighten fastening bolts (1) for simplex injection pump gear – tightening torque 28 Nm / 20.5 lbf. ft. Re-check that it is possible to remove and install Retaining Pin KM-927 for fuel injection pump under suction.
Remove
Remove all locking tools.
Install
Attach alternator to timing case and cylinder block with lower fastening bolt – do not tighten to specified torque until after installing upper fastening bolt – tightening torque 35 Nm / 26 lbf. ft.
Attach cable connections to alternator.
Install cylinder head – see operation "Cylinder Head, Remove and Install".
Remove engine from Assembly Stand KM-412, remove Adapter KM-412-8-1 and KM-412-16 from cylinder block and attach engine damping block bracket to cylinder block – tightening torque 60 Nm / 44 lbf. ft.
Install engine – see operation "Engine, Remove and Install".