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Installing plunger assemblies
1. Position the cam at the bottom dead center in the
cylinder to which the plunger assembly is in-
stalled.
2. Place the stopper plate (1) on top of the pump
case to prevent damage to the pinion and control
rack during the installation of the plunger assem-
bly.
NOTE! If the stopper plate is not used during plunger
assembly installation, the teeth on the pinion hit the
teeth on the rack, causing rough edges that hinder
smooth rack movement.
3. Hold the flange of the barrel with both hands and
press down the plunger assembly until the
bottom side of the flange contacts the stopper
plate.
4. Remove the stopper plate, and lower the plunger
assembly by serching the correct meshing slow-
ly. Do not apply excessive forte to press down
the plunger assembly. If the plunger assembly is
jammed, turn the flange by jiggling back and forth,
then press down.
5. Insert standard barrel shims (thickness: 1.0 mm
[0.04 in.] ) under each barrel flange, and align the
reference mark on the barrel flange with the align-
ment mark (1.5-mm [0.06 in.]diameter hole) on the
pump case.
IMPORTANT! In each cylinder, insert barrel
shims of the same thickness, one in front and
one in back. (Do not use two or more shims at
one location.) If the shim thickness varies in the
front and back of a cylinder, the rack may not
move smoothly, causing hunting or other prob-
lems.
6. Install washers on the barrel bolts, and screw the
bolts snug. Then, using a torque wrench, tighten
the bolts progressively and evenly to the specified
torque.
Group 23 Fuel System
165
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