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 for 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 oil pan – see operation "Oil Pan, Remove and Install",
Disconnect wiring harness plug (1) from hot film mass air flowmeter,
Detach engine vent hose (2) from cylinder head cover,
Release hose clamp (3) from air intake hose,
Remove fastening bolt (4) and remove air cleaner housing (5) with air intake hoses from brackets,
Remove cylinder head cover – see operation "Cylinder Head Cover, Remove and Install",
Remove vacuum pump from cylinder head – see operation "Vacuum Pump, Remove and Install",
Remove ribbed V-belts – see operation "Ribbed V-belts, Remove and Install",
Remove ribbed V-belt tensioner – see operation "Ribbed V-belt Tensioner Assembly, Remove and Install",
Lock engine at 1st cylinder TDC – see operation "Engine, Lock at 1st Cylinder TDC (Timing, Check)",
Remove cylinder head – see operation "Cylinder Head, Remove and Install",
Detach cable connections (1) and (2) from alternator,
Remove lower alternator fastening bolt (3) and remove alternator,
Remove ribbed V-belt guide roller (4),
Remove crankshaft Retaining Pin KM-929 (5),
Release (do not remove) fastening bolt for torsional vibration damper (1) – counterhold with KM-930 (2), with KM-977-1 if necessary,
Install
Re-insert crankshaft Retaining Pin KM-929 (4) in crankshaft pulse pick-up aperture to stop,
Inspect
In this position, the marks (3) must align,
Remove
Remove torsional vibration damper,
Remove duplex chain tensioner (1),
Detach timing case (2) from cylinder block – note different bolt lengths,
Edge out seal ring from timing case (3) with suitable tool – ensure that sealing surfaces are not damaged,
Note. If replacing the timing case, transfer the following components
- Oil pressure regulating valve
- Safety valve
- Closure Plug
- Oil Pump
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,
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,
Place Simplex fuel injection pump sprocket on injection pump flange and tighten new fastening bolts (bolt strength 10.9)hand tight - for Y 20 DTH from MY 2003 and Y 22 DTR: 5 fastening bolts.
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
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 with KM-935 (2) on protective sleeve and press in seal ring until it is flush in the timing case - use fastening bolt of the torsional vibration damper.
Caution
Remove Crankshaft Retaining Pin KM-929 (4) and Fuel Injection Pump Retaining Pin KM-927 if installed,
Install
Attach torsional vibration damper to crankshaft with new bolt (1) – counterhold with KM-930 (2), with KM-977-1 if necessary – tightening torque 150 Nm / 111 lbf. ft. + 45° + 15°,
Re-insert crankshaft Retaining Pin KM-929 (4) in crankshaft pulse pick-up aperture to stop,
Inspect
In this position, the marks (3) must align,
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,
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 and without a release pin (2).
If the design has a release pin, the chain tensioner must be relieved of tension via the release pin after installation.
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,
Install
Remove injection pump lock pin KM-927 . Tighten fastening bolts (1) with bolt strength 10.9 for Simplex fuel injection pump sprocket - tightening torque 28 Nm - for Y 20 DTH from MY 2003 and Y 22 DTR; 5 fastening bolts. Check again that injection pump lock pin KM-927 can be installed and removed under suction.
Install
Attach ribbed V-belt guide roller to support – 35 Nm / 26 lbf. ft,
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",
Attach vacuum pump to cylinder head – see operation "Vacuum Pump, Remove and Install",
Install cylinder head cover – see operation "Cylinder Head Cover, Remove and Install",
Install ribbed V-belt tensioner – see operation "Ribbed V-belt Tensioner Assembly, Remove and Install",
Install ribbed V-belt – see operation "Ribbed V-belt, Remove and Install",
Insert air cleaner housing with air intake hoses into bracket and attach to body – tightening torque 5 Nm / 4 lbf. ft,
Attach air intake hose to turbocharger – tightening torque 3.5 Nm / 2.6 lbf. ft. Attach engine vent hose to cylinder head cover. Connect wiring harness plug to hot film mass air flowmeter,
Install oil pan – see operation "Oil Pan, Remove and Install",