Note. The timing case must be removed for the following operations.
| 1 | Duplex Fuel Injection Pump Gear, 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 Tensioner Rails, Remove and Install |
| 6 | Timing Case Gasket, Replace |
| 7 | Oil Pump, Remove and Install (not illustrated in Fig. F 9839). |
Remove
Remove oil pan - see operation "Oil Pan, Remove and Install".
Remove cylinder head - see operation "Cylinder Head, Remove and Install".
Remove heat shield (1) and cable connections from alternator.
Remove fastening bolt (2) and alternator.
Caution
Remove Crankshaft Lock Pin KM-929 (3).
Remove
Release (do not remove) fastening bolt (1) for torsional vibration damper - counterhold with KM-930 (2), with KM-977-1 if necessary (in conjunction with KM-956-1).
Install
Re-insert crankshaft Retaining Pin KM-929 (3) to stop in crankshaft pulse pick-up aperture.
Inspect
In this position, the marks (4) must be aligned.
Remove
Remove torsional vibration damper.
Remove
Remove duplex chain tensioner (1).
Detach timing case (2) from cylinder block - note different bolt lengths.
Edge out seal ring (3) from timing case with suitable tool - ensure that sealing surfaces are not damaged.
Note. When replacing the timing case, the following components must be removed and checked for wear
1. Oil pressure regulating valve
2. Safety valve
3. Screw plugs
4. Fluid pump
Remove
Remove fastening bolts (1), ensure bolting strength equals 10.9, replace fastening bolts if required - remove Simplex injection pump gear with Simplex timing chain.
Caution
The factory-fitted fastening bolts of the Simplex injection pump gear must be replaced after slackening for the first time.
The factory-fitted fastening bolts of the Simplex injection pump gear do not have to be replaced after slackening for the first time.
Remove
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
Remove gasket remnants and clean sealing surfaces.
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.
Install
Place crankshaft sprocket (6) with duplex timing chain (5) and duplex fuel injection pump gear (3) on crankshaft or fuel injection pump flange.
Inspect
Check condition of spring washer, replace if necessary.
Caution
Ensure that recess in injection pump flange and the retaining bore (1) in injection pump are positioned in centre of oblong hole (2) on the Duplex 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 fuel injection pump gear on fuel injection pump flange and hand-tighten fastening bolts with bolting strength of 10.9.
Place simplex timing chain on simplex fuel injection pump sprocket and hang over timing chain tension rail (simplex).
Caution
Arrow (1) on the Simplex injection pump gear must be aligned with the recess in injection pump flange and retaining bore (2) in injection pump.
Injection Pump Lock Pin KM-927 (3) must be able to be removed and installed under suction.
Install
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 over Protective Sleeve KM-935-1 (1) and place straight on timing case.
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 Lock Pin KM-929 (1) and, if installed, Injection Pump Lock Pin KM-927.
Install
Attach torsional vibration damper (2) to crankshaft with new fastening bolt - counterhold with KM-930, with KM-977-1 if necessary (in conjunction with KM-956-1) (3) - tightening torque 150 Nm / 111 lbf. ft. + 45 ° + 15 ° .
Re-insert crankshaft Retaining Pin KM-929 (1) to stop in crankshaft pulse pick-up aperture.
Inspect
In this position, the marks (4) must be aligned.
Inspect
Arrow (1) on Simplex injection pump gear must be aligned with the recess in injection pump flange and retaining bore (2) in injection pump.
Install
Insert Injection Pump Lock Pin KM-927 (3) in lock bore of fuel injection pump.
Install
Insert duplex chain tensioner (2) in timing case - closed side of chain tensioner must face towards tension rail. Install closure bolt (4) with new seal ring (3) - tightening torque 60 Nm / 44 lbf. ft.
Caution
If a chain tensioner without release pin has been replaced during a service by a chain tensioner with a release pin, the chain tensioner must be released using the release pin after installation. Drive in the release pin with the handle of a hammer until a click is heard.
Install
Remove Injection Pump Lock Pin KM-927.
Tighten fastening bolts (1) with bolting strength 10.9 for simplex fuel injection pump gear - tightening torque 28 Nm / 21 lbf. ft.
Inspect
Re-check that Retaining Pin KM-927 for fuel injection pump can be removed and installed under suction.
Install
Attach alternator with lower fastening bolt to timing case and to cylinder block - tighten to torque only after installing upper fastening bolt - tightening torque 35 Nm / 26 lbf. ft.
Attach cable connections and heat shield to alternator.
Install cylinder head - see operation "Cylinder Head, Remove and Install".
Install oil pan - see operation "Oil Pan, Remove and Install".