Subject: Gasket Kit to Repair Oil Leaks Models: 911, 930 ALL
Bulletin Number: 77-03
If oil leaks occur, such leaks can be corrected by installing special engine gasket kit,
Part No. 930.100.909.00
Kit Installation
Work sequence (engine not removed):
- Remove air cleaner
- Remove A/C compressor (where applicable)
- Remove air pump
- Remove heater hose
- Remove A/C mounting plate (where applicable)
- Remove muffler with EGR filter
- Remove air injection lines and air pump hose
- Remove air pump support bracket
Remove back plate
- Remove A/C bracket (where applicable)
- Drain engine oil

Replace oil return tubes as follows:

Removing
- Cut tubes in half and remove
- Clean sealing areas at crankshaft and camshaft housing
Installing
- Apply thin film of oil to all O-rings on oil return tubes
- Move circlip half way down the tube
- Push short tube in and install
- Move circlip back into groove

-Remove camshaft sealing flange

- Remove heater hose with pan (left and right side) from heat exchanger
- Remove support bracket for A/C (where applicable)
- Remove plate at right side air shroud
- Remove oil lines, both sides
- Remove side pans
- Remove thermo time switch
- Remove chain guide (1 each side)
- Remove chain housing
Note:
Replace all 6 chain guides if damaged with Part No. 911.105.222.05
- Remove distributor ground wire from chain housing cover, left side
- Turn engine over until no. 1 piston is on TDC (valve timing made easier later)
- Loosen oil line, left side
- Remove lower bolt from air shroud, left side
- Remove top nut of chain housing cover, left side
- Remove chain housing cover
- Remove chain tensioner, cam gear and sprocket, complete

Replace Intermediate Shaft Gasket as Follows:
- Support engine with crane
- Remove engine mount
- Remove intermediate shaft cover
- Clean all sealing surfaces on chain housing/cover, camshaft/sealing flange and intermediate shaft/cover
- Install intermediate shaft cover with new gasket
- Install chain housing (both sides) with new gasket
- Install engine mount
- Remove crane
- Install camshaft sealing flange with new gasket and O-ring.

Install Chain Tensioner as Follows:
- Collapse chain tensioner
- Install guide rails (1 each side) in chain housing. Be sure longer part faces out.
- Install spacer shims, woodruff key, cam gear and sprocket.
- Install tensioner in position
- Time valves
- Install upper nut for chain housing, left side
- Install plate for air shroud, right side
- Install heater hose, left and right side
- Install oil line, right side
- Fasten heater hoses to heat exchanger
- Install chain housing covers with new gaskets
- Connect ground wire and thermo time switch on left cover
- Install support bracket for A/C (where applicable)
- Install end plate
- Install bracket for air pump
- Install heater hose, right side; fasten to air shroud
- Install A/C bracket (where applicable)
- Install air injection lines
- Install muffler with BGR filter
- Install air pump with belt
- Install A/C compressor with belt (where applicable)
- Attach heater hoses
- Check ignition wires for proper fit
- Install air cleaner


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