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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