SERVICE MANUAL CALIBRATION Section 5 Before  mounting  pump  on  stand  remove  access  plug with   screwdriver   bit   KDEP   2949.      Remove   fuel   inlet adapter  and  plug  opening  with  bushing  1  413  462  040 and copper gasket 2 916 710 611 so it is flush with pump housing. ESTABLISH PORT CLOSURE ON NO.  1 CYLINDER 1.  Mount pump on stand and install rack dial indicator 1 687 233 015, bracket 1 688 130 030, adapter bushing 1 683 350 065 and rack pin 1 683 201 013 (Figure 2). Figure 2.  Installing Dial Indicator (Rack Gauge) 1. Bracket    1    688    130    030    with    Adapter Bushing 1 683 350 065 and Rack Pin 1 683 201 013. 2. Dial Indicator 1 687 233 015 2. Zero dial indicator when rack is pushed to shut- off.      Be   sure   rack   does   not   bottom   out   on indicator.    Move  throttle  lever  to  max.    position Total   rack   travel   should   be   as   specified   on individual pump calibration chart for starting fuel delivery (Step 17). 3. Move rack out of starting fuel position with shut- off  lever.    Dial  indicator  should  read  about  10 mm 2 mm. 4.   Mount lift-to-port closure measuring device 1 688 130   135   with   dial   indicator   1   687   233   012, adapter bushing 1 683 350 066 and tappet pin 1 682  012  008  to  pump  (Figure  3).    Make  sure tappet   number   one   is   at   bottom   dead   center (B.D.C.).  The plunger lift-to-port closure is the distance in mm from the B.D.C.  position of the   cam   to   port   closing   by   the   plunger.      Lift-to-port closure    is    only    measured    at    element    number    one. Subsequent elements are phased at 60 degree intervals (see Step 10). 5. Zero   the   dial   indicator   at   bottom   dead   center position of the roller tappet. IMPORTANT HIGH PRESSURE PHASING IS RECOMMENDED.      (FOR   LOW   PRESSURE PHASING REMOVE DELIVERY VALVE, SPRING AND WASHER. UPON REPLACEMENT,  NEW DISCHARGE FITTING AND   GASKET   AT   BOTTOM   OF   DELIVERY VALVE    ARE    REQUIRED    EACH    TIME    AS THEY ARE A ONE-TIME TORQUE DESIGN). Figure 3.  Establishing Initial Plunger Lift (No.  1 Pumping Element) 1. Dial Indicator 1 687 233 012 2. Plunger Lift Device 1 688 130 135 with Pin 1 682 012 008 and Adapter Bushing 1 683 350 066. 6. With   the   bleeder   screw   open   at   number   one calibrating    nozzle    holder    assembly,    increase feed pressure until calibration fluid comes out of overflow tube with no bubbles. 7. Turn   camshaft   slowly   in   direction   of   rotation (clockwise)  until  port  closure  is  reached.    Port closure  is  reached  when  the  flow  of  calibrating fluid  from  nozzle  holder  overflow  tube  changes from a steady stream to drops. CGES-375 Printed in United States of America Page 2