Timing Pin: Service and Repair

REPLACING THE TIMING PIN

The timing pin can be replaced without removing the assembly from the gear housing.





Remove the timing pin by prying the retaining ring out with a small screwdriver. Replace the retaining ring if it is damaged during removal.





NOTE: If the timing pin assembly is removed from the gear housing, it must be precisely reset to obtain exact TDC. Refer to the Timing Pin Housing Assembly - Installation (With Head On) in this section of the manual.

Install a new 0-ring, lubricate the pin and position in the housing. Install the new retaining ring.

A = 1.5mm [0.059 inch]

Torque Value: 5 N-m [44 in-lbs]

TIMING PIN ASSEMBLY OR GASKET - REPLACEMENT





Locate TDC for Cylinder No.1.





Remove the timing pin assembly and gasket.





Install a new gasket and, if required, a new timing pin assembly.

Apply a coat of Loctite 59241 liquid Teflon to the threads of the Torx head screws.

Hold the pin (A) in the hole (B) in the camshaft gear to align the housing.

Torque Value: 5 N-m [44 in-lbs]

TIMING PIN HOUSING ASSEMBLY - INSTALLATION (WITH HEAD ON)





The location of the timing pin assembly on the gear housing is critical for correct engine adjustments. Follow this procedure to install the assembly so that it corresponds to Top Dead Center (TDC) for Cylinder Number 1.





Looking through the hole in the gear housing, rotate the engine until the hole in the cam gear can be seen.





Adjust the exhaust rocker lever to have zero (0) valve clearance.





Remove the injector nozzles from all of the cylinders.

NOTE: This step is important to vent the cylinders so the crankshaft can be rotated smoothly to locate TDC for Cylinder Number 1.





Temporarily install the vibration damper. Fabricate and install a wire pointer as shown.





Rotate the crankshaft one-quarter rotation in the direction opposite engine rotation.





Tighten the adjusting screw for the exhaust valve two complete turns of the screw. Tighten the locknut.





CAUTION: Use extreme care that the piston does not push against the exhaust valve with so much force that it bends the push rod.

Rotate the crankshaft slowly in the direction of engine rotation until the piston touches the exhaust valve.

Mark the vibration damper corresponding to the wire pointer.





CAUTION: Make sure that the piston touches the valve with approximately the same amount of force as in the previous step.

Rotate the crankshaft In the opposite direction until the piston touches the valve.

Mark the vibration damper again.





Measure the distance and mark the pulley at one-half the distance between the two marks. This mark is the TDC mark.





Completely loosen the exhaust valve adjusting screw.





Rotate the crankshaft approximately 180° in the direction of engine rotation until the pointer is aligned with the TDC mark. Look through the back side of the gear housing for the timing pin hole in the camshaft gear.

Reset valves on No.1 cylinder and install cover.





Apply a coat of Loctite 59241 Liquid Teflon to the threads of the torx headscrews. Hold the timing pin in the hole to align the housing.

Torque Value: 5 N-m [44 in-lbs]





Install the injectors and bleed the fuel system.





Operate the engine at idle for 5 to 10 minutes and check for leaks and loose parts.