- Set the piston of No. 1 cylinder on the compression stroke. The compression stroke occurs when the inlet valve and the exhaust valve are closed at the top of the stroke. Refer to Systems Operation, Testing and Adjusting, "Finding Top Center Position For No. 1 Piston". From the front of the engine, turn the crankshaft counterclockwise by 90 degrees.
- Remove the fuel shutoff solenoid. Refer to Disassembly and Assembly, "Fuel Shutoff Solenoid - Remove and Install".
- Remove the high pressure fuel lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove and Install".
- Disconnect the fuel supply line.
- Remove the body for fuel delivery valve (1) for the No. 1 cylinder. Disassemble the fuel delivery valve.
Note: Some fuel injection pumps may need to be removed to an upright position in order to remove the fuel delivery valve. Refer to Disassembly and Assembly, "Fuel Injection Pump - Remove".
Note: All components of the fuel delivery valve must be kept clean. Keep the components in clean diesel fuel.
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| Illustration 1 | g01123858 |
(1) Body for fuel delivery valve (2) Spring (3) Valve pin (4) Fuel injection pump (5) Drain tube | |
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| Illustration 2 | g01123860 |
Components of the fuel delivery valve (1) Body for fuel delivery valve (2) Spring (3) Valve pin (6) Location pin (7) Washer (8) Seat | |
- Reassemble the fuel delivery valve with ONLY the following components:
- Body for fuel delivery valve (1)
- Spring (2)
- Washer (7)
- Seat (8)
- Body for fuel delivery valve (1)
- Install the fuel delivery valve. Tighten the fuel delivery valve to 42 N·m (31 lb ft).
Note: Fit the fuel injection pump to the engine if the fuel injection pump was removed. Refer to Disassembly and Assembly, "Fuel Injection Pump - Install".
- Install drain tube (5) to the fuel delivery valve (1) for the No. 1 cylinder.
- Install fuel reservoir (9) with a control valve (10). Install a hose (11) from the fuel reservoir (9) to the inlet of fuel injection pump (4). Fill the fuel reservoir with 0.2 L (0.21 qt) of clean fuel.
Note: The fuel reservoir should be approximately 152 mm (6 inch) above the fuel injection pump.
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| Illustration 3 | g01123861 |
(9) Fuel reservoir (10) Control valve (11) Hose (12) Drain pan (13) Timing mark | |
- Put drain pan (12) below drain tube (5) in order to catch the fuel.
- Open the valve (10) for fuel reservoir (9). If the fuel injection pump is set correctly, then the fuel should flow through drain tube (5) .
Note: Ensure that the throttle lever is held in the maximum fuel position.
- From the front of the engine, turn the crankshaft in a clockwise direction until the flow of the fuel is reduced to 1 drop for every 7 to 10 seconds. This should be the correct timing mark (13) .
- Ensure that the timing mark (13) is correct.
Note: The static timing specifications can be found on all of the emissions labels on the timing case of all certified engines.
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| Illustration 4 | g01123866 |
(4) Fuel injection pump (14) Shim | |
- If shim (14) must be replaced, remove the fuel injection pump and the shim.
The timing will change one degree for each 0.10 mm (0.004 inch) in thickness of the shim. Thicker shims will retard the timing while thinner shims will advance the timing.
Install fuel injection pump (4) and a new shim (14) of the correct thickness. Tighten all nuts and bolts to the correct torque. Refer to the Specifications Module for additional information. Repeat steps 2 through 13 in order to ensure that the final position is correct.
Note: If a shim is not required, use a thin coat of 4C-9612 Silicone Sealant on the mating surfaces of the fuel injection pump and the cylinder block.
- When the timing is correct, remove drain tube (5), fuel reservoir (9), and hose (11) .
- Remove the body for fuel delivery valve (1). Disassemble the fuel delivery valve in order to reinstall valve pin (3) and location pin (6). Reassemble the fuel delivery valve with all of the components as the components are shown in illustration 2. Install the fuel delivery valve to fuel injection pump (4). Tighten the fuel delivery valve to 42 N·m (31 lb ft).
- Install all fuel lines in the correct position. Tighten all nuts and bolts to the correct torque. Refer to the Specifications Module for the correct torque.
- Install the fuel shutoff solenoid. Refer to Disassembly and Assembly, "Fuel Shutoff Solenoid - Remove and Install".
- Install the valve mechanism cover.
- Eliminate air from the fuel system.
- The engine must be tested on an engine dynamometer in order to check the maximum no-load speed and engine settings after assembly.