4000 Series
8
Engine timing 8
To set number 1 piston to Top Dead Centre (TDC) Operation 8-1
Special Requirement
Special Tool
Description Part Number
Engine Cranking Device SE253
1 Disconnect the batteries.
2 Fit the engine cranking device to the starter motor hole in the flywheel housing.
3 Use the flywheel housing inspection hole directly below the turbocharger to view TDC 1 (A1).
TDC
1
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8 4000 Series
Calibrating fuel injectors Operation 8-2
Special requirements
Special tools
Description Part number Description Part number
Fuel injector clamp tool T6253/147 Calibration tool T6253/177
Notes:
This operation is only required if the governor linkage inside the gearcase has been disturbed.
Ensure that the spacer (A8) is fitted between the adjustable link and the fuel control arm.
1 Fit the fuel injector clamp tool (A1) to each rocker box.
2 Tighten the adjustable screw (A2) down onto the fuel injector until the fuel control arm (A10) is able to move
freely.
3 Remove the cover (A13).
4 Using a tapered wedge (A16) between the actuator lever (A17) on the gearcase side and the coolant pipe
(A15) to set the governor to 5% open (A14).
5 Place the step side of the calibration tool (A6) with the line (A9) against the fuel control arm (A10). Move the
calibration tool and fuel control arm setting the no fuel line (A12) to the line (A11) on the fuel injector body.
6 Set the adjustable link (A7) on the centre-line measurement (A8) between the fuel control arm (A10) and the
break-back lever (A7).
7 Fit the adjustable link (A7) and torque the link to 8 Nm (6 lbf ft) 0.6 kgf m.
13
17
16
3
15
2
1
6
7
0 50% 4
8
12
9
14
10
5
A 11
D1380
8 Remove the wedge (A16).
9 To set the governor actuator lever to position fuel injector number 1 in the “calibration position”, use the
tapered wedge (A16) with the side of the fuel control arm (B1) set to the line (B2) on the fuel injector body.
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4000 Series 8
10 Check the calibration position of all fuel injectors. If the fuel control arm (B1) is past the calibration line (B2),
reset the adjustable link (B3) to bring it into position.
11 If any fuel control arm is before the calibration line, reset the governor linkage to position the fuel control
arm in line with the calibration line. Then alter the adjustable links on the other cylinders to correspond with
their calibration lines.
Warning! Do not use the adjustable link (B3) to bring a fuel control arm up to the calibration line as it will allow
the fuel injector to “fuel” when other fuel injectors are in the “no fuel position”.
12 When this operation is completed, check all fittings for tightness and ensure that ball joints move freely.
Remove the fuel injector clamp tool (B4) and the wedge (B5).
2
1
4
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8 4000 Series
Setting governor on zero fuel Operation 8-3
Special requirements
Special tools
Description Part number
Spacer tool T6253/197
1 Remove the rocker cover and the rocker shaft assembly from the cylinder head, see Operation 3-1.
2 Set the spacer tool (A1) between the break-back lever (A2) and the cylinder head face of cylinder number
1 gearcase end of the engine. This should set the governor in the zero fuel position (A3).
3 Fit the rocker cover of the cylinder head, see Operation 3-1.
Note: If the governor control shaft in the gearcase has been renewed, see Chapter 11, Fuel system.
1
3
0 5
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Applying pressure to the timing pin Operation 8-4
Caution: The timing pin is the reference point for the start of the fuel injection process, fuel injector timing.
1 Use a screwdriver to apply light pressure to the timing pin as shown in graphic (A1).
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8 4000 Series
Timing the fuel injectors Operation 8-5
Notes:
Do not use the starter motor to turn the engine.
The spill timing of the engine is recorded on the engine data plate and marked for each cylinder on the
flywheel.
Set the spill timing of the engine in the order of the positions identified in the engine plan view (A6)
1 Set the engine on Number 1 cylinder to TDC (Top Dead Centre) valves closed.
2 Set bridge piece and tappet clearance, see Chapter 3, Cylinder head assembly.
3 Turn the engine backwards until the spill mark (A7) passes the timing pointer (A8). Then turn the engine in
the normal direction of rotation until the spill is in line with the timing pointer.
4 Loosen the fuel rocker adjustable locking screw (A3).
5 Fit a 3 mm allen key (A2) through the hole in the fuel rocker adjuster (A4) and turn anticlockwise fully.
6 Apply pressure to the timing pin, see Operation 8-4.
7 Turn the fuel rocker adjuster until the timing pin is engaged, release and ensure the timing pin springs out
freely
8 Position the DTi gauge (A5) (Dial Test indicator) on top of the fuel rocker adjuster (A4) and set the dial to
zero by moving the DTi up and down the shaft (A1).
9 Turn the fuel rocker adjuster clockwise until the dial indicator reads 3 mm (0,118 in).
10 Remove the DTi gauge (A5).
11 Tighten the fuel rocker adjustable locking screw to 68 Nm (50 lbf ft).
Continued
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4000 Series 8
12 Repeat the steps 1 to 11 in order of firing sequence for all remaining cylinders (A6).
Firing Sequence
TDC Valves
1 5 3 6 2 4
closed
TDC Valves
6 2 4 1 5 3
overlap
5
6
4
1
2
3 6
8
3
2
7
14 °
SPILL
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