Checking and adjusting the valve clearance and unit injectors

Checking and adjusting the valve clearance and unit injectors

Specifications

Valve clearance, intake valve(cold engine) 0,45 mm Valve clearance, exhaust valve (cold engine) 0,70 mm Measure for unit injector (cold engine) 66,9+/-0,1 mm

Lock nut for adjusting screw on the rocker arm for the unit injector 39 Nm

Lock nut for adjusting screw on the rocker arm for the valves 35 Nm Screw for upper rocker cover 18 Nm Screw for lower rocker cover 26 Nm Bearing bracket and rocker arm shaft 105 Nm Cable connection, unit injector 2 +/- 0,2 Nm

Tightening torques

(See page 3 for general tightening torques)

Special tools

Number Designation Illustration Tool board

99 309 Tool to rotate flywheel D 5

99 414 Setting tool Measuring tool cabinet

588 179 Torque screwdriver

Order of adjustment

In order for the adjusting to be carried out on the correct revolution, proceed as follows: 1. Rotate the flywheel so that the 72° mark on the flywheel can be seen in the lower window of the flywheel housing whilst valve overlap occurs on cylinder 5. 2. Then turn the flywheel clockwise so that it passes TDCDown (0°) by about 20° and then turn it anticlockwise until TDCDown(0°) is visible in the lower window on the flywheel housing. The reason for turning past

TDCdown(0°) and then back is to counteract any backlash. You are now on the first revolution and can adjust the valves and unit injectors according to the following table. 3. Rotate the flywheel anti-clockwise using tool 99309 so that the mark on the flywheel is visible in the lower window of the flywheel housing. Flywheel seen from the rear of the engine. * Direction of rotation when adjusting. The solid line shows the order to take the angles on the first round and the broken line the order for round 2.

Revolution Mark on flywheel (degrees) Adjust unit injector rocker arm on cylinder Adjust intake and exhaust valves on cylinder Valve change on cylinder

1 TDC Down 0 2 1 1 72 5 1 144 4 2 1 216 3 1 288 5 4 2 TDC Down 0 1 2 72 (432) 3 5 2 144 (504) 2 2 216 (576) 1 3 2 288 (648) 4

If reading cannot be taken from underneath:

Turn the flywheel with tool 99309 to valve overlap on cylinder 1 (which corresponds to TDC down (0°) in the lower opening). Then turn the flywheel anti-clockwise 144° at a time and observe the valve overlap. Adjust the valves according to the table below.

Valve overlap on cylinder Adjust the valves on cylinder Adjust unit injector rocker arm on cylinder

TDCdown (0°) 1 5 5

(144°) 2 3 3 (288°) 4 1 1 (432°) 5 2 2 (576°) 3 4 4

The flywheel is also marked at 240°/600° and 120°/480°; these marks apply to 6 cylinder engines. 1. Start by rotating the flywheel so that the mark on the flywheel is visible in the lower window as illustrated. Never read off the flywheel mark in the top window - this reading will be completely wrong..

2. Fit adjusting tool 99414 with the metal plate around the unit injector.

WARNING!

When the unit injector is checked and the measurement is outside 66.9+/-0.1mm, it is necessary to be very careful when handling the unit injector. The spring is pre-tensioned and can come loose, causing personal injury.

Setting tool 99414 acts as a gauge with the measurement 66.9 mm.

3. When adjusting, loosen the lock nut and adjust the unit injector with adjusting screw1. The unit injector is correctly set when the small piston 2 is level with the flat upper surface of the tool. Check using a finger. It is possible to feel differences of less than a hundreth of a millimetre. The setting dimension is 66.9+/-0.1mm.

Refer to tables in Order of adjustment for unit injectors

The setting tool piston is above or below the flat upper surface of the tool. Adjust the unit injector. The setting tool piston is level with the flat upper surface of the tool. The unit injector is correctly adjusted.

4. Torque tighten the lock nut to 39 Nm after adjusting. 5. Remove tool 99414.

6. Fit the upper rocker cover and tighten the screws to 18 Nm.

7. Close the bleeder nipple and tighten the banjo screw.

8. Fill and bleed the fuel system, refer to Bleeding the fuel system in booklet 03:04-02.