101693-9860 ZEXEL 9 400 616 080 BOSCH INJECTION-PUMP ASSEMBLY 9400616080 1016939860 16713z6067

Fuel Injection Pump
(1) Plug (timing pin hole)2. Remove plug (1) from the fuel injection pump housing.
Timing Pin Installed
(2) 6V4186 Timing Pin3. Install 6V4186 Timing Pin (2) in the fuel injection pump housing as shown. Slowly rotate the crankshaft counterclockwise (as seen from the flywheel end of the engine) until timing pin (2) goes into the slot in the fuel pump camshaft.
Timing Position Sensor Cover
(3) Cover (4) Housing (5) Timing Solenoid (BTM)4. Remove the timing position sensor cover (3) from housing (4).5. Rotate the crankshaft clockwise 15 degrees as seen from the flywheel end of the engine. Observe the motion of the timing advance power piston through housing (4).6. Rotate the crankshaft in the counterclockwise direction as seen from the rear of the engine until the timing advance power piston moves to its fully retracted position and light pressure is applied to the timing pin (2). Do not apply excessive force to rotate the engine with the timing pin installed. Excessive force will shear off the timing pin and/or cause fuel pump damage. Apply only enough force to retract the timing actuator power piston.
Install Timing Bolt
(6) 9S9082 Engine Turning Tool (7) Timing Bolt7. Put timing bolt in the timing hole in the flywheel housing. If the bolt can be installed in the timing hole in the flywheel, the static injection timing of the fuel injection pump is correct.8. If the timing bolt does not go into the timing hole in the flywheel, the timing is not correct. Perform the following steps to adjust the fuel injection pump static timing:
Automatic Timing Advance Unit
(Governor and Fuel Pump Drive Group) (8) BoltsA. Remove timing solenoid (BTM) (5).B. Remove timing advance housing (4).C. Loosen the four bolts (8) on the timing advance. With the timing pin installed in the fuel pump and the timing bolt removed, turn the engine crank shaft clockwise as viewed from the rear of the engine a minimum of 30 degrees. Make sure that the power piston of the timing advance does not move from its fully retracted position.D. Lightly tighten two of the four timing advance bolts to 2.3 N m (21 lb ft). Finger tight only so as not to bend the timing pin.E. Rotate the crankshaft counterclockwise as viewed from the rear of the engine (direction of rotation) slowly until the timing bolt can be installed in the flywheel. The number one piston is now at top dead center.F. Tighten the four timing advance bolts (8) to a torque of 10 N m (7 lb ft). Remove the timing pin from the fuel injection pump.G. Tighten the four timing advance bolts to a torque of 55 7 N m (41 5 lb ft). Remove the timing bolt from the flywheel.H. Turn the crankshaft two complete revolutions counterclockwise as viewed from the rear of the engine to make sure that the timing advance piston is in the fully retracted position. Repeat step 6 and 7 to check the timing again to see if the timing