101608-6461 ZEXEL 9 400 615 856 BOSCH INJECTION-PUMP ASSEMBLY 9400615856 1016086461

When fuel has stopped flowing out, turn the crankshaft slightly in the reverse direction such that fuel flows out. Then, slowly turn the crankshaft clockwise again to more accurately verify the point at which fuel stops flowing out.
End of fuel flow(c) If the IT mark on the crankshaft pulley and the mark on the gear case are aligned when fuel stops flowing out the injection timing is normal.
Timing marks(3) Adjustment
(a) If the injection timing is out of specification, make adjustments by increasing or decreasing the thickness of the injection pump's mounting shim. A change of 0.1 mm in the shim thickness yields a change of approximately 1° in the injection timing.
Injection timing adjusting shim(b) Increasing the shim thickness retards the injection timing, and decreasing the shim thickness advances it. Shims come in 9 different thicknesses from 0.2 mm (0.008 in.) to 1.0 mm (0.039 in.) at intervals of 0.1 mm (0.004 in.). The thickness is not indicated on the shim, so any shim should be measured with a vernier caliper before being used.
Before using any shim, apply sealant to both sides to prevent oil leakage.
(c) After making adjustments, check the injection timing is correct.(d) Close the cock on the fuel filter, then fit the delivery valve spring and injection pipe in their original positions.
Adjusting injection timingAdjusting Idle Speed
(1) Preparation for Adjustment
(a) Warm up the engine unit the coolant reaches a temperature of 60°C (140°F) or higher.(b) Make sure the valve clearances, injection timing, and injectors are normal.(2) Adjusting Low-Idle Speed
Loosen the locknut on the idling set bolt, turn the bolt to achieve the specified low-idle speed (1000 25min-1), then tighten the lock nut to hold the bolt in that position.(3) Adjusting No-Load Maximum Speed
Loosen the lock nut on the high-speed set bolt, turn the bolt to achieve the specified no-load maximum speed (2600 +30-10 min-1), then tighten the lock nut to hold the bolt in that position.
Adjusting idle speedAdjusting Fan Belt Tension
(1) Press the fan belt with the specified force mid-way between the alternator pulley and crankshaft pulley, and observe the extent of deflection.Unit: mm (in.) (2) If the extent of deflection is out of specification, loosen the adjusting bolt and adjust the fan belt tension by moving the alternator. Retighten the adjusting bolt securely.
Adjusting fan belt tensionRunning in the Engine
After an overhaul, the engine should be tested and inspected on a dynamometer. This operation serves to run in the engine's major moving parts.Starting the Engine
(1) Before starting the engine, check the coolant, engine oil and fuel levels and bleed all air out of the fuel and cooling systems.(2) Without supplying fuel to the engine, crank the engine for about 10 seconds to permit oil to circulate through it.(3) Move the speed control lever slightly in the fuel-increase direction. (Do not move the lever to the full-injection position.) Then, turn the starter switch to the START position to start the engine.(4) Once the engine has started, set it to the low-idle speed using the speed control lever.Inspection after