2.2L Diesel Engine
See Figures 1, 2 and 3
Special tools Ford 14-0303, Static Timing Gauge Adapter and D82L4201A, Metric Dial Indicator, or the equivalents are necessary to set or check the injector timing.
- Disconnect both battery ground cables. Remove the air inlet hose from the air cleaner and intake manifold.
- Remove the distributor head plug bolt and washer from the injector pump.
- Install the Timing Gauge Adapter and Metric Dial Indicator so that the indicator pointer is in contact with the injector pump plunger and gauge reads approximately 2.0mm.
- Align the 2°ATDC (after top dead center) on the crankshaft pulley with the indicator on the timing case cover.
- Slowly turn the engine counterclockwise until the dial indicator pointer stops moving (approximately 30°-6°).
- Adjust the dial indicator to 0 (Zero). Confirm that the dial indicator does not move from Zero, by rotating the crankshaft slightly right and left.
- Turn the crankshaft clockwise until the timing mark aligns with the cover indicator. The dial indicator should read 1mm +-> 0.02mm.
If the reading is not within specifications, adjust the timing as follows:
- Loosen the injection pump mounting nuts and bolts.
- Rotate the injection pump counterclockwise (reverse direction of engine rotation) past the correct timing position, then clockwise until the timing is correct. This procedure will eliminate gear backlash.
- Repeat Steps 5, 6, and 7 to check that the timing is properly adjusted.
- Remove the dial indicator and adapter. Install the injector head gasket and plug. Install all removed parts.
- Run engine, check and adjust idle RPM. Check for fuel leaks.
See Figures 4, 5, 6 and 7
- Remove top timing belt cover.
- Rotate engine until No. 1 piston is at TDC on the compression stroke. Verify this by checking timing marks.
If engine temperature is below 122°F (6°C), bypass the cold start mechanism as follows:
- Insert a suitable tool and rotate the fast idle lever.
- Insert a spacer or a wrench at least 7mm thick between cold start advance lever and the cold start device.
- Loosen, but do not remove, the two mounting bolts and two nuts attaching the injection pump to the mounting bracket and front cover.
- To prevent the delivery valve holders from turning with the fuel line nuts, loosen, but do not remove, the nuts securing the fuel lines to the injection pump using a backup wrench.
- Remove the timing plug bolt from the center of the fuel injection pump hydraulic head.
- Install adapter Rotunda model 014-00303 or equivalent, into the port in the hydraulic head.
- Mount Tool D82L-1201-A or equivalent dial indicator, in timing adapter with a minimum preload of 0.010 in. (0.25mm).
- Rotate the crankshaft approximately 30° counterclockwise. The, set the dial indicator to zero.
- Rotate the crankshaft clockwise to 5° ATDC and check that the dial indicator indicates 1mm +-> 0.03mm.
- If the timing is out of specification, rotate the injection pump body until the dial indicator indicates specification. Rotate the pump clockwise if the reading is more than specification, or counterclockwise if less than specification. Tighten the injection pump mounting nuts to 11-15 ft. lbs. and tighten the bolts to 15-19 ft. lbs.
- After tightening injection pump mounting bolts and nuts, repeat Steps 9 and 10 to ensure that the injection timing has not changed.
- Tighten the fuel line nuts at the injection pump to 17-26 ft. lbs.
- Using a new copper gasket, install the injection timing plug bolt and tighten to 10-14 ft. lbs.
- Install the upper timing belt cover.
- Run the engine and check for fuel leaks at the injection pump.