Injection Pump Timing, Check and Adjust
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
1. Remove heater air intake
Release 2x clip (1)
| .P. S0005034.tif | 9 | 7,5 | tiff;; |
2. Remove top cover for timing belt
Pull off
| Disconnect fuel return pipe from clip | |||
|---|---|---|---|
| .P. S0005030.tif | 9 | 7,5 | tiff;; |
3. Remove top right cover for timing belt
| Remove 3x bolt (1) | |||
|---|---|---|---|
| .P. S0005031.tif | 9 | 7,5 | tiff;; |
4. Rotate crankshaft clockwise to within one tooth of TDC for No.1 cylinder
Note: No.1 cylinder is next to flywheel.
Check timing marks on pulley and timing cover
5. Remove blanking plug (arrowed) from cylinder block
Install Crankshaft Positioning Pin KM-6031
Do not fully engage
| .P. T3046.tif | 9 | 7,5 | tiff;; |
6. Remove blanking plug (1) from injection pump
| Note: Illustration shows, injection pump removed for clarity. | |||
|---|---|---|---|
| .P. T3318.tif | 9 | 7,5 | tiff;; |
7. Install Adapter MKM-571-B then Dial Gauge MK-6033 to injection pump
Insert probe of adapter until probe touches back of cam
Install dial gauge to adapter, obtain deflection of 1mm
| Zero the dial gauge | |||
|---|---|---|---|
| .P. S0005242.tif | 9 | 7,5 | tiff;; |
8. Check injection pump timing
Observe correct dial gauge reading (7.64 mm) can be found on fixed plate (1) on accelerator lever of injection pump
Rotate crankshaft clockwise until Positioning Pin KM-6031 locates fully into crankshaft
Observe dial gauge reading
| If dial gauge reading is incorrect, adjust injection pump timing | |||
|---|---|---|---|
| .P. S0005073.tif | 9 | 7,5 | tiff;; |
9. Install Locking Tool (1) KM-6239 to pulley
| Install 2x bolt (2) | |||
|---|---|---|---|
| .P. S0005135.tif | 9 | 7,5 | tiff;; |
10. Adjust injection pump timing
Note: Pulley locking nut has left hand thread.
Release pulley locking nut (1), use Gear Socket KM-6034
Turn adjuster (2), using Adjusting Wrench KM-6035-A until correct dial gauge reading is obtained
| Secure pulley locking nut (1) (20 Nm), using Gear Socket KM-6034 | |||
|---|---|---|---|
| .P. S0003656.tif | 9 | 7,5 | tiff;; |
| .D. ICON05.tif | 0,75 | 0,75 | tiff;; Install, Connect |
11. Remove Locking Tool (1) KM-6239
| Remove 2x bolt (2) | |||
|---|---|---|---|
| .P. S0005135.tif | 9 | 7,5 | tiff;; |
12. Remove Crankshaft Positioning Pin KM-6031
Rotate crankshaft clockwise two revolutions
13. Fully install Crankshaft Positioning Pin KM-6031
| Check fuel injection pump timing marks for alignment |
14. Remove dial gauge from injection pump
| Install blanking plug (1) | |||
|---|---|---|---|
| .P. T3318.tif | 9 | 7,5 | tiff;; |
15. Remove Crankshaft Positioning Pin KM-6031
| Install blanking plug (arrowed) | |||
|---|---|---|---|
| .P. T3046.tif | 9 | 7,5 | tiff;; |
16. Install top right cover for timing belt
| Install 3x bolt (1) | |||
|---|---|---|---|
| .P. S0005031.tif | 9 | 7,5 | tiff;; |
17. Install top cover for timing belt
Push fit
| Install fuel return pipe to clip | |||
|---|---|---|---|
| .P. S0005030.tif | 9 | 7,5 | tiff;; |
18. Install heater air intake
| Install 2x clip | |||
|---|---|---|---|
| .P. S0005034.tif | 9 | 7,5 | tiff;; |