Diesel MFI Pump: Adjustments

Fuel Injection Pump Timing (Static), Checking and Adjusting


Requirement
- Toothed belt tension OK
- Cold Start Accelerator knob NOT pulled out

- Remove sound dampening pan
- Tilt radiator with lock carrier out and forward
- Remove toothed belt guard for injection pump drive
- Set engine to cyl. 1 TDC

With engine removed







- Set adjusting tool to 82 mm -arrow A-
- reference point is graduation on left of vernier scale
- Install adjusting tool as shown
- Turn crankshaft until TDC mark on flywheel and tip of adjusting tool -arrow B- and marks on injection pump gear and mounting bracket are aligned

Engine installed







- Turn crankshaft until TDC mark on flywheel, boss on bell housing and marks on injection pump gear and console align -arrows-


CAUTION!
Always use a new washer for the plug, tightened to 25 Nm (18 ft lb)







- Screw in adaptor in place of plug, and install small dial gauge (0 to 3.0 mm range) with about 2.0 mm pretension

To read off dial gauge when turning injection pump drive gear, lift vehicle and turn from below. When checking start of injection by turning

crankshaft backward and forward, a second person must watch the marks on the flywheel/transmission.

- Slowly turn crankshaft anti-clockwise (opposite to normal rotation), until dial gauge needle stops moving
- Zero gauge
- Turn crankshaft clockwise (normal rotation) until TDC mark on flywheel is aligned with reference mark
- Read off start of injection on dial gauge
Test figure: 0.93... 1.07 mm stroke
Setting figure: 1.00 + 0.02 mm stroke


NOTE: If the value is within the specified tolerance, adjustment is not required.


- Adjust incorrect setting

Either

Turn injection pump after loosening mounting bolts from console and bracket

Or

Turn injection pump sprocket as follows


NOTE: To read off dial gauge when turning injection pump sprocket, lift vehicle and turn from below.







- Using 3036 counter-hold tool, hold injection pump sprocket and loosen approx. one turn
- Ensure that engine is still at TDC
- Using 3036 counter-hold tool, turn injection pump sprocket anti- clockwise (opposite to normal direction) arrow direction A - until dial gauge needle stops moving
- Zero gauge
- Using 3036 counter-hold tool, turn injection pump sprocket clockwise (normal rotation) -arrow direction B- until gauge displays:
- 1.00 ± 0.02 stroke (start of injection)
- Using 3036 counter-hold tool, hold injection pump sprocket in this position and tighten mounting bolt
- 50 Nm (37 ft lb) approx.


CAUTION!
Re-check start of injection by turning crankshaft back to zero on the dial gauge and forward to TDC (using vibration damper). This check will deviate from the set figure due to toothed belt slip.


- Start of injection must now be corrected by a 2nd adjustment taking the deviation into account

e.g.
- 1st adjustment figure = 1.00 mm
- Figure when checked = 0.93 mm
- Deviation = -0.07 mm
- 2nd adjustment figure = 1.07 mm
- After 2nd adjustment, tighten injection pump sprocket
- 100 Nm (74 ft lb)
- Install toothed belt guard, radiator with lock carrier and sound dampening pan