|
Timing Chain, Remove and Install
 Remove
Remove oil pan – see operation "Oil Pan, Remove and
Install".
Remove cylinder head – see operation "Cylinder Head,
Remove and Install".
Remove alternator – see operation "Alternator, Remove and
Install".
Remove timing case ground cable.
Detach upper coolant hose from compensation tank, radiator and
cylinder head.
Remove power steering hydraulic pump main bracket. The hydraulic
system should remain sealed. Do not stretch or kink hydraulic
hoses.
Remove bearing pin for ribbed V-belt tensioner with
KM-824-A.
Undo injection pump sprocket attachment nut.
Remove hub of torsional vibration damper – see operation
"Hub of Torsional Vibration Damper, Remove and Install".
Models with AC: remove AC compressor main bracket – see
operation "AC Compressor Main Bracket, Remove and Install".
|
Remove
Remove upper guide rail from above.
Remove timing case attachment screws (15 screws). Carefully
remove timing case. Pay attention to chain tensioner retaining pin
and locking tubes (3).
Manually tension chain tensioner (2) in direction of arrow using
lower tensioner blade (4) and insert Retaining Pin KM-823 (5).
Remove lower tensioner blade.
If replacing chain tensioner: remove chain tensioner attachment
screws (1). carefully remove chain tensioner.
|
|
|
Remove
Remove injection pump sprocket attachment nut (1).
Remove injection pump sprocket with KM-825 (2). Counterhold
KM-825 against hex (3).
Remove KM-825 from injection pump sprocket.
Remove sprockets (4) and (6) and timing chains.
Remove lower guide rail (5).
 Clean
Remove old seal and clean all sealing surfaces.
|
|
|
Install
The seal is only available for timing case and oil pump
together.
With repairs on timing case: separate seal at the marked
points.
Put on the seal.
Insert lower guide rail.
 Adjust
Turn crankshaft in engine rotation direction until markings (1)
and (2) are aligned. Connect old torsion vibration damper hub
attachment screw to crankshaft in order to do this.
|
|
|
Install
Twist injection pump with Arm KM-826 (1) until it is vertical.
Turn Arm KM-826 clockwise, until pressure point can be felt.
Place timing chain with copper links (3) and (4) on markings of
sprockets (2) and (5).
|
|
|
Install
Attach sprockets together with timing chains. Marking (1) on
injection pump sprocket must point upwards. Insert crankshaft
sprocket into the disc springs first.
Lightly press injection pump sprocket against the injection pump
stub axle and twist injection pump until injection pump sprocket
engages the injection pump stub axle disc spring. Tighten injection
pump sprocket fastening nut.
Install chain tensioner – tightening torque 16 Nm / 12
lbf. ft.
Insert lower tension rail.
Tension chain tensioner by hand along with lower tensioning rail
and remove Retaining Pin KM-823.
|
|
Carefully put on timing case. Pay attention to chain tensioner
retaining pin.
Connect attachment screws to timing case – tightening
torque 9 Nm / 6.5 lbf. ft.
Insert upper guide rail.
Install
Install AC compressor main bracket – see operation "AC
Compressor Main Bracket, Remove and Install".
Install hub of torsional vibration damper – see operation
"Hub of Torsional Vibration Damper, Remove and Install".
Attach injection pump sprocket fastening nut – tightening
torque 48 Nm / 35 lbf. ft.
Install bearing pin for ribbed V-belt tensioner –
tightening torque 65 Nm / 48 lbf. ft.
Install power steering hydraulic pump support bracket –
tightening torque 22 Nm / 16 lbf. ft.
Attach upper coolant hose to compensation tank, radiator and
cylinder head.
Install alternator – see operation "Alternator, Remove and
Install".
Attach ground cable to timing case.
Install cylinder head – see operation "Cylinder Head,
Remove and Install".
Install oil pan – see operation "Oil Pan, Remove and
Install".
Set delivery start – see operation "Check and Set Delivery
Start (Static)".
|
