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Timing Case, Remove and Install
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Note: The timing case
must be removed for the following operations.
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1
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Duplex Fuel Injection Pump Gear, Remove and Install
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2
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Duplex Timing Chain, Remove and Install
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3
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Guide Rail - Duplex Timing Chain, Remove and Install
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4
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Crankshaft Sprocket, Remove and Install
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5
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Timing Chain Tensioner Rails, Remove and Install
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6
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Timing Case Gasket, Replace
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7
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Oil Pump, Remove and Install (not illustrated in Fig. F
9839).
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 Remove
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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).
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Remove
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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.
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Remove
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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.
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Note: When replacing
the timing case, the following components must be removed and
checked for wear:
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1. Oil pressure regulating valve
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2. Safety valve
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3. Screw plugs
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4. Fluid pump
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Remove
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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.
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 Clean
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Remove gasket remnants and clean sealing surfaces.
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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
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Place crankshaft sprocket (6) with duplex timing chain (5) and
duplex fuel injection pump gear (3) on crankshaft or fuel injection
pump flange.
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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
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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).
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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
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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.
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Caution
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Remove Crankshaft Lock Pin KM-929 (1) and, if installed,
Injection Pump Lock Pin KM-927.
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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
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Arrow (1) on Simplex injection pump gear must be aligned with
the recess in injection pump flange and retaining bore (2) in
injection pump.
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Install
Insert Injection Pump Lock Pin KM-927 (3) in lock bore of fuel
injection pump.
Install
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Insert Duplex chain tensioner (5) in timing case - closed side
of chain tensioner must face towards tension rail. Install closure
bolt (3) with new seal ring (4) - tightening torque 60 Nm / 44 lbf.
ft.
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Caution
When a new duplex chain tensioner is installed, following
installation, the chain tensioner must be released via the release
pin (2). 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 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".
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