Intermediate Gear
REMOVAL - INTERMEDIATE GEAR1. 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 high pressure pump.
9. Remove cylinder head front cover.
10. Remove top slide rail.
NOTE: Note position of dowel pin for camshaft sprocket alignment during reassembly.
11. Unbolt exhaust camshaft sprocket and remove.
12. Remove the intake camshaft.
13. Remove intermediate gear and bushing (Fig. 74).
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 the intake camshaft.
3. Install exhaust camshaft sprocket, noting dowel pin alignment. Tighten bolt to 18 Nm (159 inch lbs.).
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.