7AK00001-UP Engine

⚠ Do not remove the hub nut from the shaft of the fuel injection pump. The hub is installed at the factory to ensure correct fuel pump timing position.

⚠ Do not release the torx screws. If released and the timing plate is moved, the factory timing position will be lost.

Tools: 150-3992 Timing Pin (Bosch), 150-3993 Timing Pin (Stanadyne and Delphi)

1. Remove the fuel injection nozzles, the water pump, and the cover for the gear of the fuel injection pump.
2. Rotate the crankshaft clockwise until the inlet valve on the No. 1 cylinder closes. Slowly rotate until the timing gear slot and the hub slot align with the hole in the pump body.
3. Insert the timing pin through the timing gear and the slot in the hub. Push the pin into the hole in the pump body as far as possible. The engine is then at top center of No. 1 cylinder on the compres

⚠ Be careful when you rotate the crankshaft. The No. 1 inlet valve will be held in position on top of the piston. If the crankshaft is not positioned properly, the valve may fall from the cylinder head.

Tools: 150-3992 Timing Pin (Bosch), 150-3993 Timing Pin (Stanadyne and Delphi), Temporary Pointer, 6V-3075 Dial Indicator

1. Fasten a temporary pointer to the front of the front cover. Put the tip of the pointer close to the edge of the damper or the pulley.
2. Remove the fuel injection nozzles and the valve mechanism cover.
3. Rotate the crankshaft clockwise (facing the front of the engine) until the pushrod for the inlet valve of the rear cylinder begins to tighten.
4. Rotate the crankshaft further by 1/8 of a turn clockwise. Insert a lever between the rocker lever and the valve spring cap of the No. 1 inlet valve. Open the inlet valve. Put a spacer approximately 5
5. Slowly rotate the crankshaft counterclockwise until the piston makes contact with the open valve. Make a temporary mark on the damper or the pulley aligned with the tip of the pointer.
6. Rotate the crankshaft clockwise by one or two degrees. Remove the spacer between the valve stem and the rocker lever. Rotate the crankshaft by 1/4 of a turn counterclockwise. Put a spacer approximatel
7. Slowly rotate the crankshaft clockwise until the piston makes contact with the open valve. Make another temporary mark on the damper or the pulley aligned with the tip of the pointer.
8. Make a temporary mark at the center point between the two marks on the damper or the pulley. Remove the other two marks. Rotate the crankshaft by 1/8 of a turn counterclockwise. Remove the spacer betw
9. Slowly rotate the crankshaft clockwise until the center mark made in Step 8 aligns with the tip of the pointer. The No. 1 piston is now at top center on the compression stroke.
10. Install the valve mechanism cover and the fuel injection nozzles.
11. Remove the temporary pointer from the front of the front cover.