TIMING GEAR, CHAIN

Removal sequence
1 Lock plug 14 Mobile skid shaft 29 High pressure fuel pump
2 Power steering oil hose 15 Upper mobile skid support
(See Gr37.) 16 Lower mobile skid 30 O-ring (if fuel pump support
3 Spacer 17 Camshaft control gear has a notch)
4 Power steering oil pump (exhaust) Gasket (if fuel pump support
(See Gr37.) 18 Camshaft control gear (intake) has no notch)
5 Coupling 19 Single chain 31 O-ring
6 Spacer 20 Lock plug 32 Oil pump/vacuum unit gear
7 High pressure fuel pump 21 Upper side skid 33 Power steering oil pump
(See Gr13.) 22 Lower side skid control shaft
8 O-ring 23 Lower skid 34 Power steering oil pump
9 Oil pump/vacuum unit 24 Drive gear support
(See Gr12 and Gr35.) 25 High pressure fuel pump gear 35 O-ring
10 Gasket 26 Double chain 36 Gasket
11 Oil pump coupling 27 High pressure fuel pump
12 Upper chain stretcher control shaft : Non-reusable parts
13 Lower chain stretcher 28 Locating pin

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: This work requires protection against dust.

• If fine dust enters the high pressure fuel pump, engine performance will significantly be affected. Be sure to cover
the openings after removing parts such as pipes.

NOTE
• Both chains and related parts must be replaced as a kit.
• A chain stretcher with self-locking mechanism needs to be replaced whenever it has been removed. The
chain stretcher also needs to be replaced if the piston is inadvertently removed from the chain stretcher.
• Once the pump housing is unlocked and the piston protrudes, the chain stretcher cannot be assembled
as before.

Installation sequence
36 35 34 33 31 30 29 28 27 32 26 25 24 23 22 21
20 19 18 17 16 15 14 13 12 8 7 6 11 10 9 5 4 3 2 1

Tightening torque (Unit: N·m {ft.lbs, kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Nut (high pressure fuel pump support mounting)
Nut (power steering oil pump support mounting)
Bolt (lower side skid mounting)
Bolt (lower skid mounting) 25 {18, 2.5} –
Lock plug
Bolt (high pressure fuel pump mounting)
Bolt (oil pump/vacuum unit)
Mobile skid shaft
40 {30, 4.0} –
Bolt (power steering oil pump mounting)
Lower chain stretcher
50 {37, 5.0} –
Upper chain stretcher
Bolt (oil pump/vacuum unit gear mounting) 130 {96, 13} –
Bolt (camshaft control gear mounting) 110 {81, 11} –
Bolt (drive gear mounting) 135 {100, 13.5} –
Bolt (upper side skid mounting)
10 {7.4, 1.0} –
Bolt (high pressure fuel pump mounting)
Bolt (Power steering hose mounting) 37.8 54 {28, 3.9 40, 5.5} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
O-ring Engine oil As required
Stud Loctite 243 As required

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TIMING GEAR, CHAIN
Special tools
Mark Tool name and shape Part No. Application

Stop the rotation of the engine

Cranking shaft MH063969
<Timing locating tool>

Stop the rotation of the hydraulic pow-

Power steering installer MH063965
er steering pump control shaft

Camshaft guide MH063968 Installation of overhead

Removal procedure
Work before removal
• Remove overhead lock plug.
• Crank the engine to turn the camshaft and align the threaded
lock plug hole with cam notch, and then fit into the lock
plug hole.

Removal: Power steering oil pump

• Remove the bolts with the spacers and detach the power steer-
ing oil pump.

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Removal: High pressure fuel pump

: This work requires protection against dust.

• Set the engine to top dead center at the #1 cylinder.

• Loosen bolt A, and then remove it.
• Loosen bolt B, and remove it together with the spacer.
• Remove the high pressure fuel pump from the high pressure fuel
pump support.
• Check the direction of the coupling installed on the high pres-
sure fuel pump.

Removal: Oil pump/vacuum unit

• Remove the oil pump/vacuum unit.
• Remove the oil pump coupling.

Removal: Mobile skid shaft, mobile skid

• Remove the chain stretcher: upper and lower.
• Remove the mobile skid shaft and disassemble the mobile skid:
lower and upper.

Removal: Camshaft control gear and single chain

• Remove bolts A and B, and then remove the camshaft control
gear (exhaust), camshaft control gear (intake) and single chain.
(The single chain has no preferred mounting orientation (front/
back).)

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TIMING GEAR, CHAIN
Removal: Lock plug, upper side skid
• Remove the rubber cap, the screws and the upper side skid.

Removal: Lower side skid, lower skid

• Remove the bolts and the lower side skid.
• Remove the bolts and the lower skid.

Removal: Drive gear, high pressure fuel pump gear, double

chain
• Insert an appropriate wrench (T90 Torx bit socket) into the high
pressure fuel pump control shaft to prevent the shaft from rotat-
ing.

• Remove the screw and the single chain drive gear from the high
pressure fuel pump control shaft.

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• Remove the high pressure fuel pump gear double chain and the
double chain from the high pressure fuel pump control shaft.
(The double chain has no preferred mounting orientation (front/
back).)

Removal: High pressure fuel pump control shaft, support

• Remove the high pressure fuel pump control shaft.
• Remove the nuts and the support.

Removal: Oil pump/vacuum unit gear

• Stop the rotation of the power steering oil pump control shaft by
inserting in the shaft and fastening the on the support
by means of the bolts.

• Remove the bolt and the gear from the hydraulic power steering
pump control shaft.

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TIMING GEAR, CHAIN
Removal: Power steering oil pump control shaft, support
• Remove the .
• Remove the hydraulic power steering pump control shaft.
• Remove the nuts and the support.

Installation procedure
Installation: Cranking shaft
• Using the , rotate the crankshaft and install it by inserting it
into the crankshaft hole from the cylinder lock hole.
• When rotating the crankshaft, be careful that it does not interfere
with the valve.
• Stop rotating the engine when it is in a condition that enables the
subsequent parts to be installed on it.

Installation: Support, power steering oil pump control shaft

• Lubricate the new O-ring with engine oil and install it on the sup-
port.
• Take care not to damage the O-ring.

• Apply Loctite 243 to the engine mating hole when the stud is re-
placed with a new one.
• Install a new gasket and the power steering oil pump support,
screw in the nuts, and then tighten them to a torque of 25 N·m
{18 ft.lbs, 2.5 kgf·m}.
• Install the positioning pin on the power steering oil pump control
shaft.
• Install the power steering oil pump control shaft on the inside of
the power steering oil pump support.

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• Stop the hydraulic power steering pump control shaft rotation of
the hydraulic power steering pump by inserting in the latter the
and fastening the on the support by means of the
bolts.

Installation: High pressure fuel pump support, high pres-

sure fuel pump control shaft
• If the high pressure fuel pump support has a notch for O-ring, in-
stall the O-ring. If it has no notch, install the gasket.
• If it has a notch, apply engine oil to the new O-ring and install it
to the high pressure fuel pump support.
• Be careful not to damage the O-ring during installation.
• If it has no notch, install the new gasket to the high pressure fu-
elpump support.

• There is a housing for the locating pin in the through hole in the
high pressure fuel pump gear.
• The through hole in the high pressure fuel pump gear has a ref-
erence point which needs to be kept in a vertical position when
timing the pump.
• There is a housing for the locating pin in the high pressure fuel
pump control shaft.
• The position of the housing for the locating pin in the shaft has
been determined so as to ensure the timing between the pump
and crankshaft.

• Apply Loctite 243 to the engine mating hole when the stud is re-
placed with a new one.
• Install the support and the nuts and tighten them to the pre-
scribed torque (25 N·m {18 ft.lbs, 2.5 kgf·m}).
• Install the high pressure fuel pump control shaft of the high pres-
sure fuel pump.

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TIMING GEAR, CHAIN
Installation: Oil pump/vacuum unit gear
• Install the oil pump/vacuum unit gear on the power steering oil
pump control shaft.

• Remove the bolt, and then remove the .

Installation: Drive gears, double chain

• As far as possible, install the high pressure fuel pump control
shaft with the locating pin facing directly upward.

• Position the high pressure fuel pump gear so that the chamfered
side is facing the drive gear, and install the double chain on the
high pressure fuel pump gear.
• Align the high pressure fuel pump gear with the locating pin of
the high pressure fuel pump control shaft, and then install it on
the control shaft.
• After installing the fuel pump gear, press C of the double chain,
and confirm that the chain is taut at sections A and B, and also
that the locating pin of the high pressure fuel pump gear is facing
directly upward.

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• Clean the contacting faces of the drive gear and the high pres-
sure fuel pump gear.
• Install the drive gear on the high pressure fuel pump control
shaft, and temporarily tighten the bolt (to the extent that the drive
gear can be easily rotated by hand).

Installation: Lower side skid, lower skid

• Inspect the condition of each skid, and replace any worn skids.
• Install the lower skid, then screw in the bolt and tighten it to a
torque of 25 N·m {18 ft.lbs, 2.5 kgf·m}.
• Install the lower side skid, and tighten the bolt to a torque of 25
N·m {18 ft.lbs, 2.5 kgf·m}.

Installation: Upper side skid

• Install the upper side skid, and tighten the bolt to a torque of 10
N·m {7.4 ft.lbs, 1.0 kgf·m}.
• Tighten the bolt at the rear of the lock plug to a torque of 10 N·m
{7.4 ft.lbs, 1.0 kgf·m}, then tighten the new lock plug to a torque
of 25 N·m {18 ft.lbs, 2.5 kgf·m}.

Installation: Single chain, gear

• Install the camshaft control gears (intake and exhaust) with the
stamped side of the gear facing the camshaft side.
• Install the camshaft control gear (intake) with the slot on the gear
at the position shown in the illustration, and then temporarily
tighten the bolt.
• Install the single chain on the drive gear and the camshaft con-
troller gear (intake).

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TIMING GEAR, CHAIN
• Use the largest of the three dowel pin insertion holes in the cam-
shaft control gear (exhaust).
• Place the single chain on the camshaft control gear (exhaust),
and temporarily tighten the gear mounting bolt (to the extent that
the drive gear can be easily rotated by hand).
• Then, check to see if the single chain between the exhaust and
intake camshaft control gears can be tensioned by removing the
play of the dowel pins in the insertion holes.

Installation: Lower mobile skid, upper mobile skid

• Check the condition of the lower and upper mobile skids. If the
skids are worn, replace them.
• Install the lower and upper mobile skids, and install the mobile
skid shaft on the crankshaft.
• Tighten the mobile skid shaft to a torque of 40 N·m {30 ft.lbs, 4.0
kgf·m}.

Installation: Lower chain stretcher

• Install the lower chain stretcher, and tighten it to a torque of 50
N·m {37 ft.lbs, 5.0 kgf·m}.

Installation: Upper chain stretcher

• A chain stretcher with self-locking mechanism needs to be re-
placed whenever it has been removed. The chain stretcher also
needs to be replaced if the piston is inadvertently removed from
the chain stretcher.
• Install the new upper chain stretcher, and tighten it to a torque of
50 N·m {37 ft.lbs, 5.0 kgf·m}.
• Insert an appropriate screwdriver through the opening in the
overhead and push the fin of the upper mobile skid until the pis-
ton of the upper stretcher reaches its stroke end.
• Check that tension is given to the chain when the piston is dis-
placed from the seat.
• Then, confirm that chains A, B and C are taut. (Tighten each
gear when the chains are taut.)

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Installation: Camshaft control gear (intake)
• Tighten the temporarily installed camshaft control gear (intake)
to a torque of 110 N·m {81 ft.lbs, 11 kgf·m}.

Installation: Camshaft control gear (exhaust)

• Tighten the temporarily installed camshaft control gear (exhaust)
to a torque of 110 N·m {81 ft.lbs, 11 kgf·m}.
• After installation, confirm that the part of the chain between the
exhaust and intake sides is taut.

• Insert an appropriate wrench (T90 Torx bit socket) into the high
pressure fuel pump control shaft to prevent the shaft from rotat-
ing.

Installation: Drive gear

• Confirm that the part of the single chain between the drive gear
and the camshaft control gear is taut, then tighten the drive gear
to a torque of 135 N·m {100 ft.lbs, 14 kgf·m}, and remove the
.

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TIMING GEAR, CHAIN
Installation: High pressure fuel pump

: This work requires protection against dust.

• The relative positions of the control shaft and pump axis are de-
termined by the flange installed on the pump.
• The high pressure pump needs to be installed in a balanced po-
sition (bottom dead center), which is obtained by rotating the
control shaft.
• Bosch provides a new high pressure pump in a stable and bal-
anced position (bottom dead center) with the flange installed on
the pump. Check that the pump shaft is unloaded (no tension).

• Apply engine oil to the O-ring, and then install the O-ring on the
high pressure fuel pump.
• Be careful not to damage the O-ring when installing it.
• Install the pump so that the control shaft teeth are engaged with
the coupling.
• Rotate the high pressure fuel pump (with the shaft and gear
locked) to align the bolt holes in the high pressure fuel pump
support and high pressure fuel pump.

• Fully tighten mounting bolt A on the high pressure fuel pump

support.
• Tighten two sets of bolt B and spacer.

Installation: Oil pump/vacuum unit

• Install the oil pump coupling on the inner side of the oil pump/
vacuum unit gear.
• Insert a new gasket, and install the oil pump/vacuum unit.
• Screw in the bolts of the oil pump/vacuum unit, and confirm that
the unit is installed correctly. Tighten the bolts to a torque of 25
N·m {18 ft.lbs, 2.5 kgf·m}.

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• Remove the .

Installation: Power steering oil pump

• Apply engine oil to the new O-ring, install the O-ring on the pow-
er steering oil pump, and then tighten the bolts of the power
steering oil pump to a torque of 40 N·m {30 ft.lbs, 4.0 kgf·m}.

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OVERHEAD, CYLINDER HEAD
Removal sequence
1 Engine cover (with engine cover)
2 Bracket
3 Injector bracket
4 Injector
5 Dust guard
6 Overhead (See later section.)
7 Rocker arm and hydraulic tappet
8 Gasket
9 Glow plug
10 Cylinder head (See later section.)
11 Cylinder head gasket

*a: Lock plug

: Locating pin
: Non-reusable parts

This work requires protection

:
against dust.

• If fine dust enters the high pressure

fuel pump, engine performance will
significantly be affected. Be sure to
cover the openings after removing
parts such as pipes.

Installation sequence
Follow the removal sequence in reverse.

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