ENGINE - DIESEL
REPAIRS 29 ISSUED: 09/97104.
Clean oil seal recess in timing gear.105. Lubricate oil seal with clean engine engine oil.
106. Fit crankshaft front oil seal using tools
18G 1068B and 18G 1619.107. Clean crankshaft pulley and crankshaft
108. Clean threads of crankshaft pulley nut and apply Loctite 601 to threads of nut and fit nut.
109. Position tool
18G 1618 to crankshaft and fit and tighten screws.110. Tighten crankshaft pulley nut to 195 Nm.
111. Rotate crankshaft and align crankshaft pulley to approximately 9
0° BTDC.
CAUTION: When the
valve gear is dismantled the hydraulic tappets tend to expand to their maximum
operating position. This is true for both used and new tappets. It is therefore
essential to position the crankshaft as described above to prevent possible
piston to valve contact during final assembly of the valve gear. The tappets
will require approximately 30 minutes to retract to their normal operating
position. After assembly, rotate crankshaft slowly to ensure valves clear
pistons.
112.
Remove tool 18G 1618.113. Clean fuel lift pump and cylinder block mating faces.
114. Lubricate NEW ’O’ ring with clean engine oil and fit to pump.
115. Fit fuel pump, position multiplug bracket, fit nuts and tighten to 20 Nm.
116. Fit NEW sealing washers to banjo connections and tighten bolts to 19 Nm.
117. Clean push rods and lubricate ends with clean engine oil.
118. Fit push rods.
119. Clean rocker assemblies and mating faces.
120. Fit rocker assemblies, fit nuts and tighten to 33 Nm.
121. Fit rocker cover gasket.
See this section.122. Clean engine and gearbox mating faces.
123. Ensure dowels are located in engine backplate.
124. With assistance locate gearbox to engine and align to dowels.
125. Fit nuts and bolts securing gearbox and tighten to 47 Nm.
126. Fit and tighten Allen screw securing gearbox to engine.
127. Position fuel pipes, fit pipe clamps and tighten bolts.
128. Connect reverse light switch multiplug and secure cover.
129. Clean crankshaft sensor.
130. Fit crankshaft sensor, fit bolt and tighten to 9 Nm.
131. Align harness bracket to engine backplate and fit and tighten bolt.
132. Fit engine and gearbox assembly.
See this section.CAUTION: Rotate
crankshaft slowly to ensure tappets have retracted and pistons clear valves.