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Simplex Injection Pump Sprocket and Simplex Timing
Chain, Remove and Install
 Remove
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Lock engine at 1st cylinder TDC - see operation "Engine, Lock at
1st Cylinder TDC (Timing, Check)".
Detach engine damping block adapter from timing case and remove
together with engine damping block bracket. Detach fuel lines from
fuel injection pump and place to rear.
Remove simplex chain tensioner (3) - note installation position.
Intensively heat fastening bolts (1) with hot air blower and
remove.
Caution
Use sheet metal plate or suitable heat shielding to avoid
damaging the guide rails.
Remove
Remove guide rail for Simplex timing chains upwards - note
installation position. Remove Duplex chain tensioner (2) - note
installation position.
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Remove
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Remove Test Gauge KM-932 from cylinder head and Injection Pump
Lock Pin KM-927 from lock bore.
Remove camshaft sprocket from camshaft - counterhold with
open-ended wrench on hex of camshaft.
Remove camshaft sprocket from simplex timing chain.
Note: To simplify
installation, suspend simplex timing chain at suitable point.
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Remove
Remove fastening bolts (1), ensure bolting strength equals 10.9,
replace fastening bolt if required - remove Simplex injection pump
gear.
Remove simplex timing chain upwards from cylinder head.
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.
Install
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Insert Simplex timing chain together with Simplex injection pump
gear. Hand-tighten Simplex injection pump gear with fastening bolts
and a bolting strength of 10.9.
Insert camshaft sprocket in simplex timing chain and place on
camshaft.
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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.
Insert Injection Pump Lock Pin KM-927 (3) in lock bore of fuel
injection pump.
Install
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Insert duplex chain tensioner (4) in timing case - closed side
of chain tensioner must face towards tension rail. Install closure
bolt (2) with new seal ring (3) - tightening torque 60 Nm / 44 lbf.
ft.
Caution
When installing new Duplex chain tensioner, chain tensioner must
be released by means of release bolt (1) after assembly. Push in
release bolt with hammer handle until click is audible.
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.
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Remove
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Remove Injection Pump Lock Pin KM-927.
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Install
Tighten fastening bolts (1) with bolting strength 10.9 for
simplex fuel injection pump gear - tightening torque 28 Nm / 21
lbf. ft.
Insert Injection Pump Lock Pin KM-927 into fuel injection pump
lock bore again.
Install
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Apply Test Gauge KM-932 (3) to cylinder head - pin (2) must
engage in bore (1) of camshaft.
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Install
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Tighten camshaft sprocket by hand with new fastening bolt.
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Caution
Ensure that camshaft sprocket is seated squarely on camshaft -
camshaft sprocket must sit flat against camshaft.
Install
Insert and attach Simplex timing chain guide rail (1) with new
fastening bolts (2), clean thread beforehand - ensure correct
installation position - tightening torque 8 Nm / 6 lbf. ft.
Install
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Insert carrier (1) of Adjuster KM-933 (4) vertically into
camshaft sprocket. Install Adjuster KM-933 on cylinder head.
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 Adjust
Use handle (2) to exert slight pressure on the carrier in the
direction of arrow (counter engine rotational direction) and fix in
place with holder bolt (3).
Removal and installation of Retaining Pin KM-927 for fuel
injection pump must be possible under suction. If this is not
possible, the pressure on the adapter plate must be slightly
reduced using the adjustment screw (3).
Install
Fasten camshaft sprocket to camshaft - tightening torque 90 Nm /
66 lbf. ft. + 60° + 30°.
Install
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Insert Simplex chain tensioner (4) in cylinder head - closed
side of chain tensioner must face towards tension rail. Install
closure bolt (2) with new seal ring (3) - tightening torque 60 Nm /
44 lbf. ft.
Caution
When a new simplex chain tensioner is installed, following
installation, the chain tensioner must be released via the release
pin (1).
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.
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Remove
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Remove all locking and adjusting tools.
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Adjust
At the torsional vibration damper fastening bolt, turn
crankshaft slowly and smoothly for two rotations (approx. 720°)
in direction of engine rotation until just in front of 1st cylinder
ign. TDC - mark (3) on torsional vibration damper is located just
in front of timing case lug (2).
Inspect
In this position, the cams (1) of the 1st cylinder are just
before TDC (both cams point upwards).
Install
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Insert Crankshaft Lock Pin KM-929 (1) in crankshaft pulse
pick-up aperture and simultaneously continue turning crankshaft
slowly and smoothly in direction of engine rotation using fastening
bolt for torsional vibration damper until crankshaft retaining pin
engages to the stop in cylinder block or crank web.
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Inspect
In this position, the marks (2) 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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Apply Test Gauge KM-932 (3) to cylinder head - pin (2) must
engage in bore (1) of camshaft.
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Remove
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Remove all locking tools.
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 Clean
Clean sealing surfaces on timing case cover and timing case -
cover aperture in timing case with lint-free cloth.
Install
Apply an approx. 2 mm (Dimension I) thick bead of silicone
sealing compound (grey) to timing case cover.
Caution
The application of silicone sealing compound (grey),
installation of timing case cover and tightening to torque must be
performed within 10 minutes.
Install
Attach timing case cover to timing case with new fastening bolts
- secure using 2 threaded bolts (M6) - tightening torque 6 Nm / 4.5
lbf. ft.
Install
Attach engine damping block adapter to timing case - tightening
torque 60 Nm / 44 lbf. ft.
Lower engine using engine bridge and attach engine damping block
bracket to engine damping block - tightening torque 45 Nm / 33 lbf.
ft.
Attach crankshaft pulse pick-up to cylinder block with new seal
ring - tightening torque 8 Nm / 6 lbf. ft.
Connect front exhaust pipe to return manifold with new gasket
and new fastening nuts - tightening torque 20 Nm / 15 lbf. ft.
Connect front exhaust pipe to muffler - tightening torque 12 Nm
/ 9 lbf. ft.
Install ribbed V-belt tensioner - see operation "Ribbed V-belt
Tensioner Assembly, Remove and Install".
Install vacuum pump - see operation "Vacuum Pump, Remove and
Install".
Install cylinder head cover - see operation "Cylinder Head
Cover, Remove and Install".
Install
Attach fuel lines to injection pump with new seal rings -
tightening torque 15 Nm / 11 lbf. ft.
Note: Before
assembling components of the intake system (hoses, connections,
etc.), they must be cleaned of any possible contamination (grease,
oil, etc.). When tightening the hose clamps, be sure to observe
exactly the tightening torque of 3.5 Nm / 2.6 lbf. ft.
Caution
It is only ensured that the intake system is free of leaks, thus
ensuring operational safety of the engine, if the hose clamps are
tightened correctly to the prescribed tightening torque.
Install
Install air cleaner housing with hot film mass air flow meter
and air intake hose - see illustration "Air Cleaner Housing, Air
Duct".
Note: Bleed fuel
system with KM-948 once it has been opened.
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