Installation - Intermediate Gear; Installation - Timing Chain Tensioning Rail; Installation - Timing Chain - Dodge Sprinter 2006 Manual

VA
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.
(6) St a r t t h e en gin e, a llow t o wa r m , t u r n en gin e
off a n d in spect for lea ks. Ca r e m u st be t a ke t o
obser ve t h e fu el syst em wa r n in g (Refer t o 14 - F UE L
SYSTE M - WARNING).
INSTALLA TION - INTERMEDIA TE GEAR
NOTE: Refer to appropriate injector servicing proce-
dures for cleaning of injectors and recesses.
(1) In st a ll in t er m edia t e gea r a n d bu sh in g. Tigh t en
bolt t o 40N·m (30 lbs.ft .)
(2) In st a ll t h e in t a ke ca m sh a ft (Refer t o 9 -
E NGINE /CYLINDE R
INSTALLATION).
(3) In st a ll exh a u st
dowel pin a lign m en t . Tigh t en bolt t o 18 N·m (159 lbs.
in .).
WARNING: NO FIRE, FLAMES OR SMOKING. SER-
VICE VEHICLE IN WELL VENTILATED AREA. RISK
OF INJURY FROM INHALING OR SWALLOWING
FUEL. RISK OF INJURY TO EYES AND SKIN FROM
CONTACT WITH FUEL. WEAR PROTECTIVE CLOTH-
ING.
(4) In st a ll h igh pr essu r e pu m p (Refer t o 14 -
F UE L SYSTE M/F UE L DE LIVE RY/F UE L INJ E C-
TION P UMP - INSTALLATION).
(5) In st a ll t op slide r a il (Refer t o 9 - E NGINE /
VALVE TIMING/TIMING
SP ROCKE TS - INSTALLATION).
(6) In st a ll cylin der h ea d fr on t cover (Refer t o 9 -
E NGINE /CYLINDE R H E AD - INSTALLATION).
(7) In st a ll t im in g ch a in t en sion er wit h n ew ga sket
(Refer t o 9 - E NGINE /VALVE TIMING/TIMING
BE LT/CH AIN AND
TION).
NOTE: Inspect basic position of camshaft and reset
if necessary (Refer to 9 - ENGINE/CYLINDER HEAD/
CAMSHAFT(S) - STANDARD PROCEDURE).
(8) Rem ove ca m sh a ft lockin g pin .
(9) In st a ll cylin der h ea d cover (Refer t o 9 -
E NGINE /CYLINDE R
COVE R(S) - INSTALLATION).
WARNING: NO FIRE, FLAMES OR SMOKING. SER-
VICE VEHICLE IN WELL VENTILATED AREA. RISK
OF INJURY FROM INHALING OR SWALLOWING
FUEL. RISK OF INJURY TO EYES AND SKIN FROM
H E AD/CAMSH AF T(S)
ca m sh a ft spr ocket ,
BE LT/CH AIN
SP ROCKE TS - INSTALLA-
H E AD/CYLINDE R
CONTACT WITH FUEL. WEAR PROTECTIVE CLOTH-
ING.
(10) In st a ll fu el h igh pr essu r e lin es a n d in ject or s
(Refer t o 14 - F UE L SYSTE M/F UE L INJ E CTION/
F UE L INJ E CTOR - INSTALLATION).
(11) In st a ll en gin e cover (Refer t o 9 - E NGINE -
INSTALLATION).
(12) Con n ect n ega t ive ba t t er y ca ble.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(13) St a r t en gin e a n d in spect for lea ks. Ca r e m u st
be t a ken t o obser ve t h e fu el syst em wa r n in g (Refer t o
14 - F UE L SYSTE M - WARNING).
INSTALLA TION - TIMING CHAIN TENSIONING
-
RAIL
n ot in g
NOTE: Carefully clean all mating surfaces with
appropriate solvents to assure that no grease or oil
is present during reassembly.
(1) In st a ll t en sion in g r a il on bea r in g pin
(2) In st a ll t im in g cover (Refer t o 9 - E NGINE /
VALVE TIMING/TIMING BE LT / CH AIN COVE R(S)
- INSTALLATION).
(3) In st a ll oil pa n a n d bolt s. Tigh t en M6 bolt s t o
9N·m (80 lbs.in .) a n d M8 bolt s t o 20N·m (15 lbs. ft .).
(4) In st a ll cylin der h ea d (Refer t o 9 - E NGINE /
CYLINDE R H E AD - INSTALLATION).
(5) Recon n ect n ega t ive ba t t er y ca ble.
AND
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.
(6) St a r t t h e en gin e a n d in spect for lea ks. Ca r e
m u st be t a ken t o obser ve t h e fu el syst em wa r n in g
(Refer t o 14 - F UE L SYSTE M - WARNING).
ADJ U ST M EN T S
INSTALLA TION - TIMING CHAIN
CAUTION: IT IS ESSENTIAL that the installation pro-
H E AD
cedure is followed exactly. Failure to do so will
result in severe engine damage.
CAUTION: Cover timing case recesses to prevent
foreign material from entering engine.
ENGINE 9 - 77