Timing Chain: Service and Repair
TIMING BELT/CHAIN AND SPROCKETSREMOVAL - TENSIONING AND SLIDE RAILS
NOTE: If it necessary to replace the tensioning rail, slide rail or tensioning arm, they are always replaced together.
1. Disconnect negative battery cable.
2. Remove the engine.
3. Remove cylinder head.
NOTE: Remove timing case cover carefully. Care must be taken not to damage oil pan gasket.
4. Remove timing case cover.
5. Pull the tensioning rail off of the bearing pins (Fig. 67).
6. Release the spring at the slide rail and take it off of the tensioning arm (Fig. 67).
REMOVAL - INTERMEDIATE GEAR
1. Disconnect negative battery cable.
2. Remove engine cover.
WARNING: NO FIRE, FLAMES OR SMOKING. RISK OF POISONING FROM INHALING OR SWALLOWING FUEL. RISK OF INJURY TO EYES AND SKIN FROM CONTACT WITH FUEL. POUR FUELS ONLY INTO SUITABLE AND APPROPRIATELY MARKED CONTAINERS. WEAR PROTECTIVE CLOTHING.
3. Remove fuel high pressure lines injectors.
4. Clean injectors and recesses.
5. Remove cylinder head cover.
6. Insert locking pin through first camshaft bearing cap into hole in inlet camshaft sprocket to lock inlet camshaft.
7. Remove timing chain tensioner.
8. Remove cylinder head front cover.
9. Remove top slide rail.
10. Remove high pressure pump.
11. Mark camshaft sprocket relative to timing chain.
12. Unbolt camshaft sprocket from exhaust camshaft.
NOTE: Note position of dowel pin for camshaft sprocket alignment during reassembly.
13. Secure camshaft sprocket to timing chain with tie strap.
14. Remove camshaft sprocket.
15. Remove intermediate gear and bushing (Fig. 68).
REMOVAL - TIMING CHAIN TENSIONING RAIL
1. Disconnect negative battery cable.
2. Remove cylinder head.
NOTE: Remove timing case cover carefully. Care must be taken not to damage oil pan gasket.
3. Remove timing chain cover.
4. Remove tensioning rail from bearing pin (Fig. 69).
REMOVAL - TIMING CHAIN
1. Remove cylinder head cover.
2. Remove vacuum pump.
3. Remove low pressure fuel pump and drive.
4. Remove guide rail in cylinder head.
5. Remove timing chain tensioner.
CAUTION: Cover timing case recess to prevent foreign material from entering engine.
6. Secure timing chain to camshaft sprocket with tie straps (Fig. 70).
7. Remove camshaft sprocket with timing chain attached, from camshaft.
NOTE: When fitting the thrust spindle, ensure that the thrust pin is positioned at the left timing chain pin of a chain link (Fig. 71).
CAUTION: Using the larger nut of special tool # 8950, back out both thrust spindle pieces to assure that the smaller portion of the spindle DOES NOT protrude into the crimping area. Position special tool #8948 over the timing chain rivet to be removed and tighten the larger nut of special tool # 8950 BEFORE tightening the smaller thrust spindle to separate the timing chain.
8. Using special tool #8948 and #8950, position timing chain separating tool at the timing chain of the camshaft sprocket (Fig. 72).
9. Screw the thrust pin, special tool #8950, in and separate the timing chain.
10. Unscrew the thrust spindle and remove the tool.
NOTE: DO NOT detach timing chain from camshaft sprocket.
11. Install camshaft sprocket with timing chain, to camshaft.
12. Remove pressed - out timing chain pin from chain separation tool.
13. Attach special tool 8931, timing chain retainer, to cylinder head with bolts supplied (Fig. 73).
14. Remove timing chain to camshaft sprocket tie straps.
15. Connect new timing chain and old timing chain with assembly link, assembly plate and locking element, and secure (Fig. 74) (Fig. 75).
CAUTION: IT IS ESSENTIAL that the installation procedure for the timing chain is followed exactly. Failure to do so will result in severe engine damage.
INSTALLATION
INSTALLATION - TENSIONING AND SLIDE RAIL
NOTE: Carefully clean all mating surfaces with appropriate solvents to assure that no grease or oil is present during reassembly.
CAUTION: ENSURE THAT THE SPRING IS CORRECTLY INSTALLED ON THE TENSIONING CLAMP AND SLIDE RAIL.
1. Install rail on bearing pin (Fig. 67).
2. Install timing cover.
3. Install oil pan bolts. Tighten M6 bolts to 9 Nm (80 inch lbs.) and M8 bolts to 20 Nm (15 ft. lbs.).
4. Install cylinder head.
5. Install the engine.
6. Reconnect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHES.
7. Start the engine and inspect for leaks. care must be take to observe the fuel system warning.
INSTALLATION - INTERMEDIATE GEAR
NOTE: Refer to appropriate injector servicing procedures for cleaning of injectors and recesses.
1. Install intermediate gear and bushing. Tighten bolt to 40 Nm (30 ft. lbs.)
2. Install camshaft sprocket, noting dowel pin alignment. Tighten bolt to 18 Nm (159 inch lbs.).
3. Remove tie strap retaining timing chain to sprocket.
WARNING: NO FIRE, FLAMES OR SMOKING. SERVICE VEHICLE IN WELL VENTILATED AREA. RISK OF INJURY FROM INHALING OR SWALLOWING FUEL. RISK OF INJURY TO EYES AND SKIN FROM CONTACT WITH FUEL. WEAR PROTECTIVE CLOTHING.
4. Install high pressure pump.
5. Install top slide rail.
6. Install cylinder head front cover.
7. Install timing chain tensioner with new gasket.
NOTE: Inspect basic position of camshaft and reset if necessary.
8. Remove camshaft locking pin.
9. Install cylinder head cover.
WARNING: NO FIRE, FLAMES OR SMOKING. SERVICE VEHICLE IN WELL VENTILATED AREA. RISK OF INJURY FROM INHALING OR SWALLOWING FUEL. RISK OF INJURY TO EYES AND SKIN FROM CONTACT WITH FUEL. WEAR PROTECTIVE CLOTHING.
10. Install fuel high pressure lines and injectors.
11. Install engine cover.
12. Connect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
13. Start engine and inspect for leaks. Care must be taken to observe the fuel system warning.
INSTALLATION - TIMING CHAIN TENSIONING RAIL
NOTE: Carefully clean all mating surfaces with appropriate solvents to assure that no grease or oil is present during reassembly.
1. Install tensioning rail on bearing pin
2. Install timing cover.
3. Install oil pan and bolts. Tighten M6 bolts to 9 Nm (80 inch lbs.) and M8 bolts to 20 Nm (15 ft. lbs.).
4. Install cylinder head.
5. Reconnect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHES.
6. Start the engine and inspect for leaks. Care must be taken to observe the fuel system warning.
ADJUSTMENTS
INSTALLATION - TIMING CHAIN
CAUTION: IT IS ESSENTIAL that the installation procedure is followed exactly. Failure to do so will result in severe engine damage.
CAUTION: Cover timing case recesses to prevent foreign material from entering engine.
1. Connect new timing chain and old timing chain with the assembly link, the assembly plate and the assembly locking element, and secure (Fig. 76).
NOTE: Always keep new timing chain meshed with camshaft sprocket.
NOTE: Rotate engine at crankshaft only. DO NOT crank engine and DO NOT rotate engine backward (Fig. 76).
NOTE: Draw out the end of old timing chain evenly as it becomes free, to the same extent that new timing chain is drawn in (Fig. 76).
2. Draw in new timing chain by rotating the crankshaft slowly in direction of rotation of engine until the ends of the new timing chain meet and can be connected (Fig. 76).
NOTE: Assembly link is only an assembly aid and NOT designed for engine running.
3. Remove assembly locking element, assembly outer plate and assembly link (Fig. 77).
4. Attach new timing chain to camshaft sprocket and retain.
5. Insert new riveted link and new middle plate into ends of timing chain (Fig. 78).
6. Take off retaining devise at cylinder head.
7. Remove camshaft sprocket from camshaft with timing chain secured.
NOTE: When assembling riveting tool, piece F5 is secured by a screw and D9 can move loosely on thrust spindle
8. Assemble riveting tool by inserting pieces F5 and D9 (Fig. 79).
NOTE: Ensure that the riveted link and riveting tool are aligned.
9. Press in new riveted link as far as the stop (Fig. 80).
10. Remove riveting tool to change inserts.
11. Install insert F1 on riveting tool and secure with screw (Fig. 81).
12. Install insert D8 on riveting tool (Fig. 81).
NOTE: The outer plate is held magnetically by riveting tool.
13. Insert new outer plate into the moving assembly insert.
14. Position riveting tool so that spacer webs of the guide are side by side.
15. Ensure that riveted link and outer plate are aligned (Fig. 82).
NOTE: When turning spindle of riveting tool, be sure that pins of riveted link are inserted into holes of outer plate (Fig. 82).
16. Screw in spindle of riveting tool until firm resistance is felt (Fig. 82).
17. Remove riveting tool.
18. Turn over moving assembly insert (D8) to the riveting profile.
19. Position riveting tool exactly over middle of pin.
20. Tighten riveting tool spindle to end of travel.
21. Repeat procedure for both riveting pins (Fig. 83).
22. Inspect riveting, re-rivet if required (Fig. 84).
23. Install camshaft sprocket with timing chain retained onto camshaft. Tighten camshaft bolts to 18 Nm (159 inch lbs.).
24. Remove camshaft sprocket to timing chain tie straps.
25. Install guide rail and tighten low pressure fuel pump drive to 50 Nm (37 ft. lbs.).
26. Install low pressure fuel pump.
27. Install timing chain tensioner.
28. Install vacuum pump.
29. Install cylinder head cover.
30. Install engine cover.
31. Connect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN. DO NOT WEAR LOOSE CLOTHES.
32. Start engine and inspect for leaks. Care must be taken to observe the fuel system warning.