INSPECTION

1.Insert a screwdriver (shank diameter: 8 mm) into the dedicated holes in the lever and turn the lever in the direction of the arrow in the illustration. caution Do not attempt to turn the lever with the screwdriver partially inserted in the holes. Make sure to use the dedicated holes to turn the lever. 2.Deactivate the start advancer by inserting an approximately 10 mm thick spacer into the space between the lever and the thermo wax. caution Return the lever slowly to avoid shock on the lever. 3.After carrying out the check and adjustments, remove the spacer and return the lever slowly to its original position. caution Do not pull the spacer by force when removing it. After the lever has moved all the way back, do not push it further in the return direction with a 24.5 N·m or greater force.

4.Decrease the allowance for the lift of the thermo wax plunger to 20 mm or less, then pull out the screwdriver.

2.Crank up the engine to place No.1 piston the TDC on the compression stroke. Align the notch in the crankshaft with the timing mark "0" on the gear case. caution If the dent on the hexagonal section of the camshaft faces upward, the No.1 piston is at the TDC on the compression stroke. If not, rotate the crankshaft one more turn in normal direction. Never rotate the crankshaft in reverse direction. It may cause damage to the timing chain tensioner. If the crankshaft is accidentally rotated in reverse direction, remove and reinstall the tensioner according to the correct installation procedure. 3.Make sure that the rod of the special tool protrudes 12 mm from the end of the tool body. note Projection of the push rod can be adjusted by the nut in the tool body. 4.Install a dial indicator (small) to the holder. 5.Secure the dial indicator with the screw at the position where the probe of the indicator contacts the push rod and the pointer starts moving. note Be sure to keep the pointer deflection within 0.5 mm.

6.Remove the head plug and gasket from the injection pump and install the special tool in that place. 7.Screw in the special tool Measuring device (MH063302) up to the position where the point of the dial gauge starts moving. note If the above position is difficult to fix, stop screwing within one turn from the start of the pointer deflection.

8.Turn the crankshaft clockwise again till No.1 piston is set 30° before TDC on the compression stroke. 9.Zero the dial gauge. 10.Turn the crankshaft a little (2 to 3°) clockwise and counter clockwise and check that the dial gauge still reads "0".

11.Set No.1 cylinder piston to the injection timing by turning the crankshaft clockwise. At this point, read the dial gauge to measure the valve lift. Fuel injection timing: 9° ATDC Plunger lift: 1 ± 0.3 mm note The timing mark scale is graduated 2° apart. 12.If the reading deviates from the specified standard value make necessary adjustment as follows.

1.Loosen the injection pipe union nut as well as the bolt and nut holding the fuel injection pump in this order. caution When loosening the union nuts, lock the delivery valve holder with a wrench to prevent it from turning together. Do not remove the union nuts, bolt and nuts. Just loosen.

2.Adjust the injection timing the injection pump assembly right or left till the dial gauge reads the specified value. Left: In case the reading exceeds the specified standard value. Right: In case the reading is below the specified standard value. 3.After the adjustment, check again to see if the dial gauge indicates the specified plunger lift.

4.Retighten the nuts and bolt in the order of nut, bolt and union nut. Specified torque: 23 N·m caution When torquing the union nuts, lock the delivery valve holder with a wrench to prevent it from turning together.

5.Remove the special tool Measuring device (MH063302). 6.Replace the gasket with a new one, and tighten the head plug to the specified torque. Specified torque: 17 N·m