Distributie dti

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Timing, Adjust – Option 1: injection pump locking pin cannot be inserted
Note: Crankshaft is locked at "1st cylinder TDC" with Lock Pin KM-929,

Remove simplex chain tensioner (3) and duplex chain tensioner (2) – note installation position. Remove fastening bolt for camshaft sprocket from camshaft – counterhold with open-ended wrench on hex of camshaft,
Insert new bolt for camshaft sprocket and tighten hand-tight – ensure that the camshaft sprocket is not tilted on the camshaft. Camshaft sprocket must lie plane on the camshaft,
Release fastening bolts (1) for Simplex fuel injection pump sprocket - note bolt strength 10.9, replace fastening bolts - for Y 20 DTH from MY 2003 and Y 22 DTR: 5 fastening bolts.
Turn fuel injection pump sprocket until arrow (1) on simplex fuel injection pump sprocket aligns with recess in fuel injection pump flange and lock bore (2) in fuel injection pump,
Insert Injection Pump Lock Pin KM-927 (3) to stop in lock bore fuel injection pump,
Insert duplex chain tensioner (4) in timing case – closed side of chain tensioner must face towards tension rail. Install closure bolt (2) with new seal ring (3) – tightening torque 60 Nm / 44 lbf. ft,
Caution
A distinction must be made between designs with and without a release pin (1).
If the design has a release pin, the chain tensioner must be relieved of tension via the release pin after installation.
Inspect
Press in the release pin with a hammer shaft until a click is heard,
It must be possible to push in release bolt up to stop with thumb and for it to slide back to its original position automatically – the release bolt can no longer be pushed in once the oil pressure has built up,
Remove Injection Pump Lock Pin KM-927,
Install
Tighten fastening bolts (1) with bolt strength 10.9 for Simplex fuel injection pump sprocket- tightening torque 28 Nm - for Y 20 DTH from MY 2003 and Y 22 DTR: 5 fastening bolts.
Insert Injection Pump Lock Pin KM-927 into fuel injection pump lock bore again,
Apply Test Gauge KM-932 (3) to cylinder head – pin (2) must engage in bore (1) of camshaft – if necessary, turn camshaft at hex (short path),
Caution
Turn camshaft carefully and smoothly,
Insert carrier (1) of Adjuster KM-933 (4) vertically into camshaft sprocket. Install Adjuster KM-933 on cylinder head,
Adjust
Use handle (2) to exert slight pressure on the carrier in the direction of arrow (counter engine rotational direction) and fix in place with holder bolt (3),
Injection Pump Lock Pin KM-927 must be able to be installed and removed under suction. If this is not the case, decrease the pressure on the carrier disk slightly via the holder bolt,
Install
Fasten camshaft sprocket to camshaft – tightening torque 90 Nm / 66 lbf. ft. + 60° + 30°,
Insert simplex chain tensioner (4) in cylinder head – closed side of chain tensioner must face tension rail. Install closure bolt (2) with new seal ring (3) – tightening torque 60 Nm / 44 lbf. ft,
Caution
A distinction must be made between designs with and without a release pin (1).
If the design has a release pin, the chain tensioner must be relieved of tension via the release pin after installation.
Inspect
Press in the release pin with a hammer shaft until a click is heard,
It must be possible to push in release bolt up to stop with thumb and for it to slide back to its original position automatically – the release bolt can no longer be pushed in once the oil pressure has built up,
Remove all locking and adjusting tools,
At fastening bolt of torsional vibration damper, turn crankshaft two turns (approx. 720°) in engine rotational direction to just before "1st cylinder TDC" – mark (3) on torsional vibration damper is just before lug (2) on timing case,
Inspect
In this position, the cams (1) of the 1st cylinder are just before TDC (both cams point upwards),
Install
Insert Crankshaft Lock Pin KM-929 (1) in aperture for crankshaft pulse pick-up and simultaneously slowly turn crankshaft further in engine rotational direction at fastening bolt of torsional vibration damper until crankshaft lock pin engages to stop in cylinder block or crank web,
In this position, marks (2) must align,
Arrow (1) on simplex fuel injection pump sprocket must align with recess in fuel injection pump flange and lock bore (2) in fuel injection pump,
Insert Injection Pump Lock Pin KM-927 (3) in lock bore of fuel injection pump,
Note: If the lock pin cannot be inserted, the entire adjustment procedure must be repeated,
Apply Test Gauge KM-932 (3) to cylinder head – pin (2) must engage in bore (1) of camshaft,
Note: If the test gauge cannot be inserted, the entire adjustment procedure must be repeated,
Remove
Remove all locking tools,
Install removed components – see operation "Engine, Lock at 1st Cylinder TDC (Timing, Check)",