|
Adjusting the timing: Option 1
Lock pin of injection pump does not fit in
retaining bore of injection pump flange
Note: Crankshaft is
locked at "1st cylinder TDC" with Lock Pin KM-929.
 Remove
|
|
Detach engine damping block adapter from timing case. Remove
simplex chain tensioner (3) and duplex chain tensioner (2) - note
installation position. Detach fastening bolt for camshaft sprocket
from camshaft - counterhold with open-ended wrench at camshaft
hex.
Install
Insert new fastening bolt for camshaft sprocket and hand-tighten
- ensure that the camshaft sprocket is seated squarely on the
camshaft. The camshaft sprocket must be seated flush on the
camshaft.
Remove
Release fastening bolts (1) for Simplex injection pump gear -
ensure bolting strength equals 10.9, replace fastening bolt if
required.
Caution
The factory-fitted fastening bolts of the Simplex injection pump
gear must be replaced after slackening for the first time.
The factory-fitted fastening bolts of the Simplex injection pump
gear do not have to be replaced after slackening for the first
time.
|
|
 Adjust
|
|
Turn injection pump gear until the arrow (1) on the Simplex
injection pump gear is aligned with the recess in injection pump
flange and retaining bore (2) in injection pump.
|
|
Install
Insert Injection Pump Lock Pin KM-927 (3) to stop in lock bore
fuel injection pump.
Install
|
|
Insert Duplex chain tensioner (4) in timing case - closed side
of chain tensioner must face towards tension rail. Install closure
bolt (2) with new seal ring (3) - tightening torque 60 Nm / 44 lbf.
ft.
Caution
When installing new Duplex chain tensioner, chain tensioner must
be released by means of release bolt (1) after assembly. Push in
release bolt with hammer handle until click is audible.
It must be possible to push in release bolt up to stop with
thumb and for it to slide back to its original position
automatically - the release bolt can no longer be pushed in once
the oil pressure has built up.
|
|
Remove
|
|
Remove Injection Pump Lock Pin KM-927.
|
|
Install
Tighten fastening bolts (1) with bolting strength 10.9 for
simplex fuel injection pump gear - tightening torque 28 Nm / 21
lbf. ft.
Insert Injection Pump Lock Pin KM-927 into fuel injection pump
lock bore again.
Install
|
|
Place Test Gauge KM-932 (3) on cylinder head - pin (2) must
engage in camshaft bore (1) - if necessary turn camshaft slowly and
smoothly at hex (short route).
|
|
Install
|
|
Insert carrier (1) of Adjuster KM-933 (4) vertically in camshaft
sprocket. Mount Adjuster KM-933 to cylinder head with accompanying
bolts.
|
|
Adjust
Use handle (2) to exert slight pressure on the carrier in the
direction of arrow (counter engine rotational direction) and fix in
place with holder bolt (3).
Removal and installation of Retaining Pin KM-927 for fuel
injection pump must be possible under suction. If this is not
possible, the pressure on the adapter plate must be slightly
reduced using the adjustment screw (3).
Install
Fasten camshaft sprocket to camshaft - tightening torque 90 Nm /
66 lbf. ft. + 60° + 30°.
Install
|
|
Insert simplex chain tensioner (4) in cylinder head - closed
side of chain tensioner must face tension rail. Install closure
bolt (2) with new seal ring (3) - tightening torque 60 Nm / 44 lbf.
ft.
Caution
When a new simplex chain tensioner is installed, following
installation, the chain tensioner must be released via the release
pin (1).
Inspect
Press in the release pin with a hammer shaft until a click is
heard.
It must be possible to push in release bolt up to stop with
thumb and for it to slide back to its original position
automatically - the release bolt can no longer be pushed in once
the oil pressure has built up.
|
|
Remove
|
|
Remove all locking and adjusting tools.
|
|
Adjust
At the torsional vibration damper fastening bolt, turn
crankshaft slowly and smoothly for two rotations (approx. 720°)
in direction of engine rotation until just in front of 1st cylinder
ign. TDC - mark (3) on torsional vibration damper is located just
in front of timing case lug (2).
Inspect
In this position, the cams (1) of the 1st cylinder are just
before TDC (both cams point upwards).
Install
|
|
Insert Crankshaft Lock Pin KM-929 (1) in crankshaft pulse
pick-up aperture and simultaneously continue turning crankshaft
slowly and smoothly in direction of engine rotation using fastening
bolt for torsional vibration damper so that crankshaft retaining
pin engages to the stop in cylinder block or crank web.
|
|
Inspect
In this position, the marks (2) must be aligned.
Inspect
|
|
Arrow (1) on Simplex injection pump gear must be aligned with
the recess in injection pump flange and retaining bore (2) in
injection pump.
|
|
Install
Insert Injection Pump Lock Pin KM-927 (3) in lock bore of fuel
injection pump.
Install
|
|
Place Test Gauge KM-932 (3) on cylinder head - pin (2) must
engage in the camshaft bore (1).
|
|
Remove
Remove all locking tools.
Install
Install removed components - see operation "Engine, Lock at 1st
Cylinder TDC (Timing, Check)".
|
