Usage:
NOTE: This procedure must be followed carefully if the fuel injection pump:
- * is to be replaced
- * performance is not correct
- * locking screw is released after the pump is removed from the engine.
- * performance is not correct
These engines operate at a static timing very close to top center (TC).
When the piston is close to (TC) there is a relatively large movement of the crankshaft for only a small movement of the piston.
When the piston is further down the cylinder, there is a relatively small movement of the crankshaft for a large movement of the piston. Therefore greater accuracy is possible. For this reason the crankshaft is set at 100° before (TC).
Use 127-1069 Timing Pin (1) to accurately set the piston to 100° before (TC).
Timing Pin
(1) 127-1069 Timing pin.
1. Remove the fuel lines from the number 1 nozzle.
2. Loosen the bolts that hold the nozzles.
3. Remove the nozzle together with its seat washer from number 1 cylinder.
4. Remove the whistle from the 127-1069 Timing Pin. Install 127-1069 Timing Pin (1). If the timing pin will not seat, rotate the engine crankshaft 180°. Put the nozzle clamp on the pin and tighten the bolts gradually and evenly to 12 N·m (9 lb ft). Install the whistle to 127-1069 Timing Pin (1).
| NOTICE |
|---|
Be sure that the piston comes lightly into contact with the timing pin, or both the piston and the pin could be damaged. |
5. Slowly rotate the crankshaft clockwise, from the front, until the piston just comes into contact with timing pin (1). The engine will now be set at 100° before (TC). If the whistle was heard slightly before contact was made with the pin, you are on the compression stroke. If not, remove the pin, rotate the crankshaft about 270° clockwise from the front. Install the pin and clamp, and slowly rotate the crankshaft until contact is made between the piston and pin. A whistle should be heard this time. The whistle confirms the engine is on the compression stroke.
6. Loosen the locking screw and position the spacer so that the locking screw will not tighten on it. Tighten the locking screw to 10 N·m (7 lb ft). Check that the spacer is free to move. The pump is now locked.
| NOTICE |
|---|
Use a second wrench to prevent movement of the high-pressure outlet when the union nut for each high-pressure pipe is loosened. |
7. Remove the pipes, the cables and the connection for the cold start device from the fuel pump. Loosen the nuts on the pump flange.
8. Remove the four bolts that hold the gear cover. Remove the gear cover from the timing case cover. Loosen the nut which retains the drive gear of the pump one to two turns.
9. Install the 8S2264 Puller Group and loosen the gear on the drive shaft of the pump. Remove the puller group. Remove the nut and the spring washer from the shaft of the fuel pump.
| NOTICE |
|---|
Do not turn the crankshaft when the pump is not on the engine; the loose fuel pump gear may damage the timing case. |
10. Remove the nuts from the flange of the fuel pump and remove the pump.
NOTE: When the pump is held, do not apply pressure to the alloy components.
11. Hold the pump securely. Install 9U6189 Drive Adapter (2) for the 9U6188 Timing Tool to the drive shaft of the pump. Use the nut for the drive gear to hold the adapter, tighten the nut finger tight.
Drive Adapter
(2) 9U6189 Drive Adapter.
12. Loosen locking screw (4) on the timing tool and set the timing tool to the correct locking angle, see the chart below for the correct angle.
NOTE: There will be more fuel pump angles defined later as these fuel injection pumps become more common.
13. Tighten locking screw (4). Install the 9U6188 Timing Tool, together with sleeve (5), to 9U6189 Drive Adapter (2) on the pump.
14. Loosen the locking screw (3) and slide the pointer (6) forward until it is over the center of the pump flange and tighten locking screw (3).
Timing Tool Installed
(3) Locking screw. (4) Locking screw. (5) Sleeve. (6) Pointer. (7) Mark.
15. Loosen the locking screw on the fuel pump and position the spacer so that the locking screw will not tighten on it. Turn the timing tool in the direction of pump rotation, see the arrow on the pump data plate, until the slot in the pointer is accurately aligned with mark (7) on the pump flange. Tighten the locking screw on the fuel pump to 10 N·m (7 lb ft). Check that the spacer is free to move. The pump is now locked.
16. Remove the timing tool and its spacer. Remove the nut and 9U6189 Drive Adapter (2) from the shaft of the pump.
17. Inspect the O-ring and, if necessary, install a new O-ring. Lightly lubricate the O-ring with clean engine oil and put the pump in position on the timing case. Be sure that the key is engaged correctly in the keyway of the drive gear.
18. Install the spring washer and the nut to hold the drive gear. Tighten the nut to 15 N·m (11 lb ft).
19. Hold the top of the pump toward the engine to remove the backlash and install the nuts to the pump flange. Tighten the nuts to 22 N·m (16 lb ft).
20. Loosen the locking screw on the fuel pump and position the spacer so that the locking screw will tighten against the spacer. Tighten the locking screw to 10 N·m (7 lb ft). Check that the spacer cannot move. The drive shaft of the fuel pump is now free to move.
21. Tighten the nut for the drive gear to 80 N·m (60 lb ft). Install the gear cover.
22. Remove timing pin (1) and install the nozzle together with a new seat washer. Tighten the bolts of all of the nozzles gradually and evenly to 12 N·m (9 lb ft).
| NOTICE |
|---|
Use a second wrench to prevent movement of the high-pressure outlet when the union nut for each high-pressure pipe is tightened. |
23. Install the pipes, cables and connection for the cold start device to the pump.
24. Remove air from the fuel system, see page 7.
25. Operate the engine and check for leakage.