604 L4-2304cc 23L XD-2 Diesel MFI Pump Adjustments
Diesel MFI Pump: Adjustments
1.
Remove valve cover.
2.
Rotate crankshaft until No. 4 cylinder is at TDC on compression stroke, with valves for No. 1 cylinder in "rocking" position, then rotate crankshaft
90 degrees opposite the normal direction of rotation.
3.
Compress No. 4 exhaust valve spring and slide rocker arm over.
4.
Rotate crankshaft in normal direction of rotation until valves for No. 1 rockers are in "rocking" position.
5.
Remove valve keepers, retainer and spring from No. 4 exhaust valve.
NOTE: Valve stem length will prevent it from dropping into cylinder.
6.
Mount dial indicator with plunger bearing against No. 4 exhaust valve stem.
7.
Bring No. 4 cylinder to TDC, preload indicator approximately 8 mm (.315 inch) and zero dial indicator.
8.
Rotate crankshaft approximately 90 degrees opposite normal direction of rotation, then rotate crankshaft in normal direction until No. 4 pistion is
.276 inch (7 mm) before TDC.
9.
Pump must be completely clean. Clean hydraulic head and loosen piston inspection plug.
10.
Turn pump shaft to bring double tooth on pinion in line with double groove in drive sprocket hub.
11.
Coat new gasket with grease and position on pump flange.
12.
Install pump onto engine and install mounting bolts without tightening them.
13.
Rotate pump body away from engine (full retard).
14.
Remove piston plug, then install dial indicator 8.0117F with extension 8.0117T, support 8.0117P abd reducer 8.0117S.
15.
Turn engine and located BDC and TDC points on pump piston. At BDC, dial indicator should have slight preload.
16.
Zero the pump's dial indicator at BDC.
17.
Turn engine so piston No. 4 is at TDC on compression stroke. Check zero point of engine dial indicator.
18.
Rotate crankshaft approximately 90 degrees opposite normal direction of rotation.
19
Rotate crankshaft in normal direction of rotation until No. 4 piston is positioned as follows:
a. On XD2C engines piston should be .97 mm (.0381 inch) before TDC.
b. On XD2S turbocharged engines, except 1984 Californnia models with pump No. R 131-R 131/1, piston should be .4 mm (.0157 inch) before
TDC.
c. On 1984 XD2S California engines with pump No. R 131-R 131/1, piston should be .51 mm (.0200 inch) before TDC.
20.
Rotate pump toward engine (advance) until dial indicator on pump shows lift of .5 mm (.0197 inch).
21.
Tighten front and rear pump mounting bolts.
22.
Check timing by turning engine 1-3/4 turns in normal direction then slowly continue turning crankshaft until indicator on pump shows lift of .5 mm
(.0197 inch). No. 4 piston should be within .02 mm (.00078 inch) of setting value specified in step 19.
23.
Install inspection plug with new gasket.
24.
Install valve spring, valve keepers, and retainer of No. 4 exhaust valve.
