101603-2324 ZEXEL 9 400 615 047 BOSCH INJECTION-PUMP ASSEMBLY 9400615047 1016032324 220204722b

If the crankshaft is not in the correct position when the magnetic pickup sensor is installed, the magnetic probe will be damaged when the engine is started.
F. Put a 2D6392 O-Ring Seal on the end of the Magnetic Pick-up Sensor (a small amount of clean engine oil will let the seal slide onto the sensor more easily).G. Push the sensor through the adapter until it comes in contact with the counterweight and move the O-Ring Seal down against the adapter.H. Withdraw the sensor 1 mm (.04 in.) and hand tighten the nut on the adapter sleeve to firmly hold the timing probe in position.I. Connect cable for magnetic pick-up to the magnetic pick-up sensor. Step 2. Install ECAP And Injector HarnessA. Connect an ECAP to the Engine Data Link Connector (J8).B. Install the Injection "T" Harness on the Fuel Injector Connector (J5/P5) in the valve cover base.C. Be certain all connections (probe, harness, ECAP) are made correctly. Use special care when connecting "T" Harness to J5. The plug can be mis-aligned. Also use care when reconnecting J5 and P5. Incorrect installation will result in a "No Start" condition. Step 3. Calibrate Speed/Timing SensorA. Start the engine and run at low idle until the engine has warmed up enough to change out of Cold Mode operation. The "Diagnostic Lamp" should go out after the engine has started and the 10 second lamp test is complete. The engine rpm will decrease from approximately 1000 rpm while in the cold mode to the programmed low idle rpm when out of Cold Mode.B. Check for ACTIVE Diagnostic Codes. Use the procedures in this manual to troubleshoot and repair any ACTIVE Diagnostic Codes before attempting a calibration check.C. After engine has shifted out of Cold Mode, select the 3176 Timing Calibrate Screen on the ECAP. To insure the most accurate timing calibration, the engine rpm should be held as steady as possible at approximately 1500 rpm. This can be performed using the hand throttle. Any major changes (greater than 100 rpm) will slow down the procedure and make it less accurate.D. Press on the "space" key on the ECAP and wait until the ECAP indicates timing is CALIBRATED (approximately 15 seconds).E. Verify that timing has been calibrated by observing the "Desired Timing" bar display on the ECAP. Run the engine at different rpm's, allowing a few seconds at each setting for the rpm to stabilize. * If the ECAP display reads that injection timing is CALIBRATED, but during verification, the actual timing bar display is not within the two vertical timing tolerance lines and/or the display is erratic, repeat the timing calibration procedure.* If the ECAP display reads UNABLE TO CALIBRATE TIMING, the electronic injection timing has NOT been set. OK: Timing is functional and calibrated if the right end of the bar graph display stays within the vertical bars at all steady speeds. NOT OK: Recheck the tool installation and tool operation. Verify that the engine speeds were kept stable ( 50