Service manual
FUEL
INJECTION
PUMP
TESTING
INJECTION
TIMING
1. Remove the air intake/silencer assembly.
2. Remove the four high pressure injector lines that connect
between the injection pump and injectors.
3. Remove the bolt and gasket installed on the distributor
head
of
the injection pump.
4. Remove the valve rocker cover.
S.
Rotate the crankshaft in normal direction
of
rotation using
the front crankshaft pulley nut and place the No. 1 piston
at
IDe
of
its compression stroke.
(No.1
piston is first
from the front
of
the engine).
NOTE:
To
verify,
the
rocker arms
of
No.4
cylinder should
be
rocking,
one
opening,
one
closing.
6. Remove the snap ring from the end
of
the rocker shaft at
cylinder No. 1 along with the retaining washer.
7. Loosen the rocker arm adjusting bolt so as to allow the
arm to be removed from the push rod and slide it off the
rocker shaft.
8. Press down on the valve and spring assembly and ensure
the valve is hitting the top
of
the No. 1 piston. Then
remove the cap, keepers and valve springs from the No. 1
valve.
NOTE:
Ensure
the
valve moves freely
in
its
guide.
Take
care
to
not
drop
the
keepers
down
the
push
rod
hole.
9. Position a dial indicator gauge on the valve stem and,
using the front crankshaft pulley nut, rock the crankshaft
counterclockwise and clockwise to to locate the exact
IDe
of
the compression stroke for the No. 1 piston.
Then zero the indicator gauge to the valve stem (the
gauge should be able to measure up to
0.3 inch
of
valve
movement).
~::.-
__
~tf====1~5.21
mm
BTDC
r-
(0.205
in)
t
10. Slowly turn the crankshaft in the opposite direction
of
normal rotation until the indicator reads 0.180 ± .005
inches
BIDe.
It is advisable to go slightly more than
0.180 inches and then return to that figure to remove gear
lash. The
No.1
piston is now at 30°
BIDe.
Verify the scribe mark on the injection pump outboard
mounting flange is properly aligned with the scribe mark
on the engine mounting case.
At
the six o'clock position
on the outboard side
of
the injection pump is a semi-oval
cover with two screws. Remove this cover and locate the
sealing
O-ring and timing washer 0.032 inches in thickness.
11. Remove the plug and sealing washer from the aft center
of
the injection pump. The plug is centrally located where
the four high pressure injector lines attach to the pump. In
place
of
the plug install the Mazda tool #49 9140 074
measuring device. Ensure the measuring device rod con-
tacts the plunger inside the pump and then zero the
gauge.
PLUG
AND
v.mIN.
WASHER
FUEL
INJECTION
PUMP
0
NOTE:
When
setting
the
dial
gauge,
confirm that
the
dial
gauge pointer
does
not deviate from the
scale
make
of
zero
by slightly turning
the
engine crankshaft from left
to
right.
Turn the engine crankshaft in the normal direction
of
rotation to bring the No. 1 piston up to
IDe.
The dial
indicator on the valve stem should zero and the indicator
on the injection pump should show
0.039 inches
(1
mm)
of
movement.
ADJUSTING
INJECTION
TIMING
1. Loosen the nuts holding the injection pump to the engine.
(The high pressure injector lines should not be attached to
the injection pump.)
2. Make the adjustment by moving by moving the injection
pump itself. When the amount
of
movement
of
the mea-
suring device indicator on the injection pump is too large,
first
tum
the injection pump in the reverse direction
of
the
engine rotation so that the dial gauge pointer indicates
less than the scale mark
of
0.039 inches
(1
mm). These
adjustments are to tighten the gear backlash.
Injection
Pump
Gear
Lock
Nut
Torque
29
-
51
ft-Ib
(4.0
-
7.4
m-kg)
When the amount
of
the measuring device indicator on
the injection pump is too small,
tum
the injection pump in
the direction
of
normal engine rotation so that the measur-
ing device indicator points to the scale mark
of
0.039
inches
(1
mm).
3. After the adjustment, tighten the injection pump
hold-
down nuts, and then confirm again that the adjustment has
been done correctly.
Remove this washer and replace the cover.
~
WESTERBEKE
Engines & Generators
32