- Set the engine to the top center position on No. 1 cylinder on the compression stroke. Refer to 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 engine speed actuator, high pressure fuel lines, and the fuel supply line from the fuel injection pump.
- Ensure that the throttle lever is held in the maximum fuel position.
- Remove delivery valve holder (1) for the No. 1 cylinder.
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 | g00839578 |
(1) Delivery valve holder (2) Spring (3) Delivery valve (4) Fuel injection pump (5) Drain tube | |
- Remove delivery valve (3) from the holder.
- Reinstall delivery valve holder (1) and spring (2). 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.
- Install drain tube (5) to delivery valve holder (1) for the No. 1 cylinder.
- Install fuel reservoir (6) with a control valve (7). Install a hose (8) from fuel reservoir (6) 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 2 | g00826712 |
(6) Fuel reservoir (7) Control valve (8) Hose (9) Drain pan (10) Timing mark | |
- Put drain pan (9) below drain tube (5) in order to catch the fuel.
- Open control valve (7) for fuel reservoir (6). If the fuel injection pump is set correctly, then the fuel should flow through drain tube (5) .
- 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 (10) .
- Ensure that timing mark (10) is correct with Table 1.
Show/hide table
Table 1 Engine description Maximum Rated Engine Speed (RPM) Injection Timing (BTC) C1.5 1500 14° ± 1° C1.5 1800 14° ± 1° C2.2 1500 12° ± 1° C2.2 1800 12° ± 1°
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| Illustration 3 | g00826730 |
(4) Fuel injection pump (11) Shim | |
- If shim (11) 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 (11) of the correct thickness. Tighten all nuts and bolts to the correct torque. Refer to Specifications for additional information.
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 (6), and hose (8) .
- Remove delivery valve holder (1). Assemble all of the components of the fuel delivery valve. 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 Specifications for the correct torque.
- Install the engine speed actuator.
- 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.