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Timing system gear assembly and injection pump

9.8.1 Timing system gear assembly

 

  1. Check that the key A is correctly fitted on the camshaft B.
  2. Position the gear C on the camshaft B adhering to the key reference A.
  3. Screw capscrew D until the end.
  4. Tighten the middle gear pin H, in the housing J of the crankcase, with the screws K (tightening torque 25 Nm).

 
Fig 9.51
Important
  • The fitting of the middle gear pin H has only one position, the 4 screw holes K are asymmetric.
  • Always replace the gasket L at each assembly.

 

 

  1. Insert the shoulder ring M.
  2. Check the integrity of the bushing N into the middle gear P, and ensure that it is free from impurities.
  3. Thoroughly lubricate the pin H and the bushing N.
  4. Position the gear P on the pin H observing all the marks W of the gears C and S (Fig. 9.54).
Fig 9.52
Important
  • Failure to comply with the marks W on the gears C, P and S, causes engine malfunction and serious damage.
  1. Insert the shoulder ring Q and the lock ring R.
  2. Tighten the screw D (Fig. 9.51 - tightening torque at 100 Nm).
Fig 9.53
Fig 9.54
Important
  • Always replace the gaskets at each assembly.
  • Check that the perforated screw AF is free of impurities inside.
  • Lubricate the thread and under the head of the AF screw with Molyslip.
  1. Position the gear unit AH on the bushing AM to centre.
  2. Secure the gear AH using the screw AF inserting the gasket AG (tightening torque at 40 Nm).

Fig. 9.55
  1. Loosen and tighten the screw AF again (tightening torque at  20 Nm + 20°).
  2. Insert the gear AN in the flange AP.
  3. Insert the shoulder ring AQ on the flange AP and clamp the gear AN using the retainer ring AR.

 

Fig. 9.56

 

 

Fig. 9.57
  1. Insert the centring ring AS in the flange AP.
  2. Secure the plate AT using the screws AV on the flange AP (tightening torque at 20 Nm)

Fig. 9.58

9.8.2 Injection pump

 

Important
  • Always change screws T with new ones or alternatively apply Loctite 270 (Fig. 9.59) to the threads.

 

 

  1. Perform the operations described in the warning in Par. 6.1.5.
  2. Place a dial gauge to detect the TDC on piston N° 1 , then bring the indicator of the dial gauge to 0.

NOTE: During the detection phase of the TDC, check that cylinder N° 1 is in compression phase (align the notches W as in Fig. 9.33).

 


Fig 9.59
  1. By means of the identified pump code, refer to Tab. 6.1 to know the advance degrees and the corresponding value to lower the piston.
  2. Mount tool ST_34 in the seat of starter motor H (Fig. 9.61) and fix it with two motor fixing screws.
  3. Having identified the value to lower the piston, rotate the crankshaft anti-clockwise by going beyond the value described in Tab. 6.1, once again, rotate the crankshaft clockwise stopping at the correct advance value by using tool ST_03 - ST_34 .
  4. Lock the ST_34 , ensure that the crankshaft does not rotate, which would alter the correct advance value.
    If this happens, repeat the instructions described in points 4, 5 and 6.


Fig 9.60
  1. Fix pump Z into housing V by means of screws T (Fig. 9.59 - tightening torque at 25 Nm).
  2. Position the gear AC onto shaft AB of the pump.

 

NOTE: You are not required to respect the reference Q gear AE (Fig. 9.61).

 

  1. Insert washer U and tighten nut AD (tightening torque at 70 Nm).


Fig 9.61

 

Wait Loading