Power Take-Off Drive Chain, Removing And Installing

Special tools and workshop equipment required 

• Locking Pin 3242
• Diesel Injection Pump Locking Pin 3359
• Crankshaft Key T40049
• 3.3 mm diameter drill bit

Removal 

• The transmission is removed.

-- Remove the timing chain cover lower section. Refer to LOWER TIMING CHAIN COVER, REMOVING AND INSTALLING .

-- Attach the Crankshaft Key T40049 the back of the crankshaft using two old drive plate bolts -arrows-.

Fig 1: Identifying Key T40049 At Rear On Crankshaft And 2 Old Bolts For Dual-Mass Flywheel

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-- Remove the bolt -arrow- for the "TDC" marking from the upper part of the oil pan by using a long hex socket wrench with a ball head.

Fig 2: Identifying Locking Bolt Of Upper Part Of Oil Pan

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-- Install the Crankshaft Holder3242 in the hole and tighten to 20 Nm. Turn the crankshaft -1- back and forth slightly to completely center the bolt, if necessary.

Fig 3: Identifying Crankshaft Holder 3242

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Fig 4: Identifying Chain Sprocket Bolts -Arrows-

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-- Lock the rear balance shaft on the engine using the Diesel Injection Pump Locking Pin 3359 and loosen the bolts -arrows- for balance shaft chain sprocket.

-- To protect against cuts, wrap the point and the cutting edges on a 3.3 mm drill bit with insulating tape.

Fig 5: Identifying Chain Tensioner, Drive Chain, And Balance Shaft -3- Chain Sprocket

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-- Push the slide rail for the chain tensioner in the -direction of the arrow- and then lock the chain tensioner using a 3.3 mm drill bit -item 4-.

-- Remove the bolts -1- and -2- and remove the chain tensioner, chain sprocket -3- for the balance shaft and the chain.

Installation 

Fig 6: Identifying Crankshaft Holder 3242

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• Tightening specifications. Refer to POWER TAKE-OFF DRIVE CHAIN OVERVIEW .
• Secure the crankshaft -1- in "TDC" position using the Locking Pin 3242.

-- Lock the rear balance shaft -arrow- to the engine with the Diesel Injection Pump Locking Pin 3359.

Fig 7: Identifying Rear Balance Shaft -Arrow- And Diesel Injection Pump Locking Pin 3359

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-- Install the chain tensioner with the chain and the drive chain and the balance shaft chain sprocket.

Fig 8: Identifying Chain Tensioner, Drive Chain, And Balance Shaft -3- Chain Sprocket

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• The slots in the chain sprocket -3- must be in the center position to the threaded holes in the balance shaft.

-- Tighten the chain tensioner bolts -1- and -2-.

-- Install the chain sprocket bolts -arrows- loosely.

Fig 9: Identifying Chain Sprocket Bolts -Arrows-

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• It must still be possible to rotate the chain sprocket on the balance shaft and it must not tip.

-- Remove the drill from the alignment hole.

Fig 10: Push A Screwdriver In The -Direction Of The Arrow-

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-- Push a screwdriver in -direction of arrow- against the chain tensioner guide rail while tightening the chain sprocket bolts -1-.

-- Remove the Diesel Injection Pump Locking Pin 3359.

Install in reverse order of removal. Note the following:

-- Install the timing chain cover lower section. Refer to LOWER TIMING CHAIN COVER, REMOVING AND INSTALLING .

-- Fill engine oil and check the oil level. Refer to Maintenance Booklet 406.