Disassembly and Assembly
Install tooling (C) as shown, and loosen the fuel
pump drive gear from the taper on the fuel injection
pump camshaft. Remove tooling (C), the bolt, washer
and fuel pump drive gear.
Remove the bolts and plate (4) that hold Idler gear
(5) in position. Remove the idler gear. If necessary,
remove the bearing from the idler gear with tooling (D)
and a press.
Do not turn the crankshaft after camshaft gear (6)
has been removed. Turning the crankshaft will
cause damage to the valves.
Remove the four bolts that hold camshaft gear (6) to
the camshaft. Remove the camshaft gear.
Install Timing Gears 1206-012
Engine Turning Tool Group
Make an alignment of the "C" marks on crankshaft
gear (3) and camshaft gear (4). Install the camshaft
gear and the bolts that hold it. Tighten the bolts to a
torque of 55 + 7 Nm (41 + 5 lb.ft.).
Install the bearing in idler gear (1) with tool (A). The
end of the bearing must be 1.52 mm (.060 in.) below the
face of the gear hub after installation.
Be sure the oil hole in the shaft for idler gear (1) is
open. Put idler gear (1) and plate (2) in position on the
shaft, and install the bolts that hold them.
Make sure tooling (C) is in position in the groove of
the fuel injection pump camshaft.
Put fuel injection pump drive gear (5) in position on
the fuel injection pump camshaft. Put washer (6) in
position on the gear with the largest diameter toward the
front of the engine. Install bolt (7), and tighten it to a
torque of 7 Nm (5 Ib.ft.).
NOTE: Make sure bolt (7) does not turn while the
flywheel is being turned.
Remove the timing bolt from the flywheel, and use
tooling (B) to turn the flywheel in the opposite direction of
engine rotation. Turn the flywheel until the "C" mark on
the crankshaft gear moves 30".