Required special tool
- Mot. 1054 TDC lock.
- Mot. 1079 LUCAS Pump Adjustment Tool Kit.
- Mot. 1200 Mot. 1317 Tool for fixing the injection pump pulley.
- Mot. 1358, Mot. 1359 RAM pulley tool kit (with high-precision angle adjustment).
Tightening torques, Nm
- RAM pulley nut (for locking in the adjusted position): 90.
Installation
Attention! The crankshaft can be rotated only in the direction of its rotation and only by rotating the front wheel, after engaging the fifth gear; if you accidentally turn the crankshaft in the opposite direction, then repeat the procedure for checking or adjusting the position of the pulley.
Checking the setting of the initial injection advance angle of high-pressure fuel pumps equipped with a RAM pulley
1. Turn the crankshaft two turns in the direction of rotation (spinning the front wheel, and engaging fifth gear).
2. Remove the plug that blocks access to the adjustment channel located on the pump cover.
3. Install tool Mot. 1079 and the indicator needle to zero so that the indicator leg extension touches the pump lobe in the non-operating position (To do this, turn the crankshaft slightly in the direction of rotation).
Note. To ensure measurement accuracy and sufficient movement of the indicator leg, it is recommended to install the indicator leg on the support mandrel with a preload of 1 mm, and fix the indicator in this position by setting its arrow to zero.
Composition of tool Mot. 1079:
A - Indicator leg extension;
B - Indicator support;
C - Indicator with measurement scale up to 30 mm.
4. Lock the crankshaft with tool Mot. 1054, for this.
- turn the crankshaft in the direction of rotation (clockwise when viewed from the timing end);
- at the same time, watching through the hatch holes in the upper cover of the gas distribution mechanism for the appearance of a mark on the camshaft pulley;
- half a tooth before the mark on the camshaft pulley aligns with the hatch mounting lug, stop rotating the crankshaft;
- insert retainer Mot. 1054
- keep pressing on the latch;
- slowly rotate the crankshaft until the latch enters the groove on the crankshaft;
- using an arrow-type indicator, check the stroke of the pump plunger;
- the value is indicated on the plates fixed on the load lever;
- if the values do not match, change the position of the pulley (not less).
Modification of tool Mot. 1358
To adjust the position of the HTD2 pulleys, it is imperative to perform this revision by shortening all three legs of the fixture by 1.5 mm.
Setting the initial injection advance angle on the injection pump with a RAM pulley
1. Remove the RAM pulley cover.
2. Fit pulley locking tool Mot. 1317 or Mot. 1200.
Attention! Using tool Mot. 1359, slightly loosen bolt 1 (be careful: left hand thread), so that flange B can be rotated.
3. Insert the tabs of the modified tool Mot. 1358 in three holes on flange B.
4. Rotate the fixture with the flange so that the three tabs of the fixture fit into the three recesses on the adjusting bolt plate.
5. Turn tool with flange clockwise until tool Mot. 1358; this is necessary to set the pulley to the transitional adjustment position.
6. Remove tool Mot. 1317 or Mot. 1200.
7. Turn the crankshaft two turns in the direction of rotation (turning the front wheel into fifth gear).
8. Remove the plug that blocks access to the adjustment channel located on the pump cover.
9. Install tool Mot. 1079 and the indicator arrow to zero in the zone of no effect of the pump cam (To do this, turn the crankshaft slightly in the direction of rotation).
10. Lock the crankshaft with tool Mot. 1054.
Note. If the length of the cable is not sufficient to adjust, turn the tool back one turn to tighten the cable using tool Mot. 1358 and resume adjustment from the previous operation.
11. Leave retainer Mot. 1054
12. Using tool Mot. 1359 pre-tighten screw 1 with a torque not exceeding 2 Nm (screw has a left-hand thread).
Attention! The torque wrench used must ensure that screws with left-hand threads are tightened.
13. Remove retainer Mot. 1054.
14. Fit pulley locking tool Mot. 1377 or Mot. 1200.
15. Turn the crankshaft counterclockwise by hand until the locking tool contacts the pulley.
16. Tighten bolt 1 to 9 Nm using tool Mot. 1359.
17. Turn the crankshaft two turns and check once again that the initial injection advance angle is set correctly.