17 . Fit the injection pump(s) together with the calculated shim thickness . Turn the engine so that the cam for the pump is not in the lifting position . Check that the pump's pin locates in the control rod's groove and that the pump(s) and the locks markings coincide (see figure) . Check after C . Turn cylinder no . 1 to it's injection . position . Place the guide pin (2) in the setting-disc's hole marked cyl . 1 . Turn the crankshaft a little against the normal direction of setting-disc's guide pin (2) goes in the timing cover's hole . Measure using a caliper the distance between the cylinder block and the roller lifter's edge (do not measure on the roller) .
rotation and thereafter in the normal rotation direction until the fitting each pump that the control rod operates easily . Tightening torque for the nuts is 20 Nm (2,0 kpm) (14.7 ft .lbs) . Connect the fuel pipe between the pumps and the pipe from the fuel filter to the injection pump . NOTE! The hole bolt for the return hose has a smaller through-flow channel than the others (on later versions it is marked 'Out") . The distance should be : 2001 : 55 .8 mm (2 .1 9685 in) 2002, 2003 : 55,6 mm (2 .18504 in) 2003T : 55 .9 mm (2 .2007 in) Example : 2001 .
If the measured distance is 55 .2 mm (2 .17323 in) this means that a shim with thickness 0 .6 mm (0 .02362 in) is to be placed between the caliper and the block . 2002, 2003 . If the measured distance is 55 .0 mm (2 .16535 in) this means that a shim with thickness 0 .6 mm (0 .02362 in) is to be placed between the caliper and the block. The measured shims thickness (in this example 0 .6 mm) is The total shim thickness is foun d by adding the block's measurements and the pump's marking . to be stamped into the block as in fig . 15 . Example The block's measurements 6 (= 0 .6 mm/0 .02362 in) The pump's marking 2 ( = 0 .2 mm/0.007874 in) No .
of shims 0 .8 mm In this case choose two soft shims 0 .2 and 0 .3 mm (0 .007874 and 0 .011811 in ) and one hard shim of 0 .3 mm (0 .011811 in) . Place the hard shim between the two soft ones and refit the pump . NOTE! A hard shim must never be fitted together with another hard shim or directly against the block or pump . Hard shims are available in thicknesses 0 .3, 0 .6 and 0 .9 mm (0 .011811, 0 .02362 and 0 .035433 in) . Soft shims are available in thicknesses 0 .2 and 0 .3 mm (0,007874 and 0 .011811 in) . 18 . Install thefeed pump and thefuel filter . Also install the thermostat housing with the thermostat . NOTE! Do not forget the lifting eyelet between the fuel filter and the D .
Repeat the procedure for the other pumps (2002, 2003) in the same way as for cylinder 1 . The setting-disc's marking is explained under point B . thermostat housing .