108621-2051 ZEXEL 9 400 619 098 BOSCH INJECTION-PUMP ASSEMBLY 9400619098 1086212051 me121067

Illustration 2 g06542023
(T1a) Eccentric gasket
Install adjustment tool (T1) on the injector for center cylinder (2) using eccentric gasket (T1a). Install eccentric gasket (T1a) over the check valve in place of the O-ring.
Illustration 3 g06542029
(T1b) Supply fitting
(T1c) Purge hose
(T2) Inlet hose
Connect a suitable container filled with clean diesel fuel to supply fitting (T1b) using inlet hose (T2). Place a small cup under purge hose (T1c).
Illustration 4 g06536094
(1) Drive clutch side cylinder
(2) Center cylinder
(3) Alternator side cylinder
(A) TDC index mark
Rotate the engine in the direction of rotation (clockwise) until center cylinder (2) is at Top-Dead-Center (TDC) with the compression stroke. The reference mark for center cylinder (2) must be aligned with the TDC index mark (A) and the valves must be closed.
Illustration 5 g06536129
Center cylinder (2) at 11° Before-Top-Dead-Center (BTDC)
(1) Drive clutch side cylinder
(2) Center cylinder
(3) Alternator side cylinder
(A) TDC index mark
Illustration 6 g06542031
(T1c) Purge hose
Raise the fuel container above the level of the injector. Rotate the engine counterclockwise until reference mark (2) is to the left of the 11° Before-Top-Dead-Center (BTDC) mark or until fuel is observed flowing from purge hose (T1c).
Illustration 7 g06542019
(T1c) Purge hose
Rotate the engine clockwise and stop immediately when the fuel stops flowing from purge hose (T1c). The beginning of injection has been reached when the fuel stops flowing.
Illustration 8 g06536129
Center cylinder (2) rotated 11°
(1) Drive clutch side cylinder
(2) Center cylinder
(3) Alternator side cylinder
(A) TDC index mark
Observe the alignment of the reference mark for center cylinder (2) and the 11° BTDC mark.Note: If mark (2) aligns with the 11° mark, timing is correct and proceed to Step 9. If marks are not aligned, the injector timing must be adjusted. Adjust injector timing using the procedure in Step 8.
Observe the position of the reference mark for center cylinder (2) and the mark at 11° of rotation for BTDC. Note if the injector timing is early or late.Note: If the reference mark for center cylinder (2) is left of the 11° BTDC mark, injector timing is early. If the mark is to the right, injector timing is late.
Illustration 9 g06536148
(B) Jam nut
Rotate the engine to align the reference mark for center cylinder (2) and the 11° BTDC mark. Loosen jam nut (B) on the fuel injector timing adjustment screw. For late timing, proceed to Step 8b. For early timing, proceed to Step 8c
Illustration 10 g06536146
(C) Adjustment screw
Late Timing: While watching purge hose (T1c), turn adjustment screw (C) clockwise until fuel flow stops.
Early Timing: While watching purge hose (T1c), turn adjustment screw (C) counterclockwise until fuel flow starts. Then, turn adjustment screw (C) clockwise until fuel flow stops.
Hold adjustment screw (C) and tighten jam nut (B) securely. Check the injector timing by repeating Steps 5 through 7.
Remove adjustment tool (T1) and install with eccentric gasket (T1a) on the injector for drive clutch side cylinder (1). Rotate the engine 120° clockwise using the reference mark for cylinder (1). Repeat Steps 4 through 8.
Repeat Step 9 for alternator side cylinder (3).
Illustration 11 g06543249
(1) 562-0435 O-Ring Seal
Remove adjustment tool (T1) and eccentric gasket (T1a). Reinstall the fuel rail with four new