Note. The timing chain can be replaced without dismantling the engine. Using the tools listed below, the new chain can be connected to the old chain, passed around the sprockets and minted.
Attention! If assembled incorrectly, the valves may collide with the piston crowns!
General information
Installation details of timing drive elements
1 - Setting marks for bringing the engine to the TDC position of the end of the compression stroke of the first cylinder; 2 - Check the correct alignment of the alignment marks of the camshafts; 3 - Assembling the chain tensioner; 4 - When removing / installing the injection pump, the crankshaft should be brought to a position of 15°after the TDC of the piston of the first cylinder; 5 - The injection pump sprocket bolt has a left-hand thread; 6 - Locking bolt; 7 - The M11 bolt of the camshaft sprocket must be replaced if its installation length «X» exceeds the limit value (53.6 mm); 8 - Crankshaft pulley bolt
The following special tools are required to perform the removal and installation procedures for the timing drive components:
- Crankshaft hub / pulley puller - No. 103589003300;
- Crankshaft sprocket puller - No. 102589053300;
- Flywheel/drive plate locking tool - No. 601589024000;
- M6-90 mm bolts for blocking the flywheel / drive disc;
- Tool for blocking injection pump - No. 601589052100;
- Tool for separating the injection pump - No. 601589000800;
- Tool for centering the injection pump sprocket - No. 601589051400;
- Set of gas distribution chain links - No. 602589024000;
- Timing chain link puller (element 1) - № 602589023300;
- Timing chain link puller (element 2) - № 602589046300;
- Timing chain link puller (element 3) - № 602589046301;
- Tool for installing gas distribution chain links - No. 602589003900;
- Set of 1 stamp holders for installing gas distribution chain links - No. 602589026300;
- Set of 2 stamp holders for installing gas distribution chain links - No. 602589036300;
- Device for fixing the chain on the camshaft sprocket - No. 602589014000;
- Tool box - No. 602589009800;
- Viscous coupling holder (series 129/140) - № 120589140700;
- Viscous clutch key - No. 111589020100;
- Pulley holder - No. 603589004000.
Pay attention to the following points:
- Unless otherwise stated, turn the engine in the normal direction only;
- Observe the tightening torques of the fasteners stipulated by the regulations;
- With the appropriate configuration, do not forget to mark the installation position of the CKP sensor before removing it;
- Do not turn the crankshaft using the camshaft sprockets, as well as other timing sprockets;
- Do not turn the crankshaft and camshafts with the timing chain removed;
- After installing the valve timing, do not forget to check the settings of the injection pump.
Servicing Timing Drive Components
Installation details of timing drive elements
1 - Setting marks for bringing the engine to the TDC position of the end of the compression stroke of the first cylinder; 2 - Check the correct alignment of the alignment marks of the camshafts; 3 - Assembling the chain tensioner; 4 - When removing / installing the injection pump, the crankshaft should be brought to a position of 15°after the TDC of the piston of the first cylinder; 5 - The injection pump sprocket bolt has a left-hand thread; 6 - Locking bolt; 7 - The M11 bolt of the camshaft sprocket must be replaced if its installation length «X» exceeds the limit value (53.6 mm); 8 - Crankshaft pulley bolt
1. Disconnect the negative cable from the battery.
2. Remove all glow plugs to make cranking easier.
3. Bring the crankshaft to the TDC position of the piston of the first cylinder (1).
4. Check the correct alignment of the alignment marks of the camshafts (2).
5. Before proceeding with the repair procedures, remove the tensioner assembly (3).
6. When removing / installing the injection pump, the crankshaft should be brought to a position of 15°after the TDC of the piston of the first cylinder (4).
7. Before removing the bolt (5) install sprocket centering tool no. 601589051400.
Note. The injection pump sprocket bolt has a left-hand thread.
8. After removing the injection pump, install the locking bolt (6), - tool no. 601589052100.
9. At installation of an asterisk of a camshaft track correctness of an arrangement of a directing pin.
10. Before installing, fill the tensioner by lowering it with the plunger down into a container with SAE 10 engine oil and depressing the plunger 7-10 times. Check the plunger for smooth travel and adequate compression resistance.
11. Having completed the necessary reconditioning, install the tensioner (3) to its position.
Note. The M11 bolt of the camshaft sprocket must be replaced if its installation length «X» exceeds the limit value (53.6 mm) (7) (see illustration 78.1).
12. Tighten the crankshaft pulley bolt (8) with a force of 320 Nm (bolt A classification 10.9) or 200 Nm + 90° (bolt B classification 8.8).