| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A(1) | 9U-6198 | Crankshaft Turning Tool | 1 |
| A(2) | 9U-7336 | Housing | 1 |
| 5P-7305 | Engine Turning Tool | 1 | |
| B | 230-6284 | Timing Pin (Camshaft) | 1 |
| C | 230-6283 | Timing Pin (Crankshaft) | 1 |
| D | 9U-7324 | Indicator Bracket | 1 |
| 7H-1942 | Dial Indicator | 1 | |
| 3S-3268 | Indicator Contact Point | 1 | |
| 7H-1940 | Universal Attachment | 1 | |
| (1) | The Crankshaft Turning Tool is used on the front pulley. |
| (2) | This Tool is used in the aperture for the electric starting motor. |
| NOTICE |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
| NOTICE |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. |
Note: The fuel injection pump must remain locked until the procedure instructs you to unlock the fuel injection pump.
- Ensure that number one piston is at the top center position on the compression stroke. Refer to the Systems Operation, Testing and Adjusting, "Finding Top Center Position for No. 1 Piston".
Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
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Illustration 1 g01343058 Typical example - Ensure that Tooling (C) is installed in Hole (Y) in the front housing. Use Tooling (C) in order to lock the crankshaft in the correct position.
Note: Do not use excessive force to install Tooling (C). Do not use Tooling (C) to hold the crankshaft during repairs.
- Ensure that Tooling (B) is installed into Hole (X) in camshaft gear (1).
- Ensure that shaft (9) on the fuel injection pump is clean, dry and free from damage.
- Ensure that the fuel injection pump is locked in the correct position. Refer to Disassembly and Assembly, "Fuel Injection Pump - Install".
- Ensure that the fuel pump gear is clean, dry and free from wear or damage. If necessary, replace the fuel pump gear.
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Illustration 2 g01335384 Alignment of timing marks Show/hide table
Illustration 3 g01343060 Typical example Show/hide table
Illustration 4 g01440103 - Install fuel pump gear (3) to shaft (9) of the fuel injection pump. Ensure that the timing Marks on gears (2) and (3) are in alignment and that the mesh of the gears is correct.
- Install a new spring washer (10) and install nut (8) to shaft (9) of the fuel injection pump. Apply sufficient pressure to the fuel injection pump gear (3) in a counterclockwise direction in order to remove the backlash. Tighten nut (8) to a torque of
24 N·m (17 lb ft) . Unlock the fuel injection pump (5).In order to unlock the fuel injection pump, loosen locking screw (5) on the fuel injection pump. Rotate spacer (6) in order to allow locking screw (5) to tighten against the spacer. Tighten the locking screw against the spacer to a torque of
12 N·m (106 lb in) . This will prevent the locking screw from tightening against the shaft of the fuel injection pump. - Remove Tooling (B) and Tooling (C).
- Tighten nut (8) to a torque of
90 N·m (66 lb ft) . - Use Tooling (D) to measure the backlash of gears (2) and (3). Ensure that the backlash for the gears is within specified values. Refer to Specifications, "Gear Group (Front)" for further information.
- Lubricate the teeth of the gears with clean engine oil.
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- Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install".