2. Drain the coolant.
3. Disconnect the coolant bypass hose.
4. Unscrew the plug of the distributor head and remove the gasket.
5. Install the pointer indicator through the adapter into the opening of the distribution head.
6. Disconnect the cold start advance changeover switch:
a) Using a screwdriver, turn the control lever approximately 20° counterclockwise.
b) Install a metal plate 8-10 mm thick between the lever and the plunger of the cold start system thermostat.
7. Set the piston of the first cylinder to TDC, aligning the timing mark on the crankshaft pulley with the TDC indicator on the oil pump housing.
8. Turn the crankshaft counterclockwise so that the mark on the pulley does not reach the mark on the oil pump housing by 25-30°.
9. By slightly turning the crankshaft left and right, make sure that the indicator arrow does not move away from zero.
10. Turn the crankshaft clockwise, when the piston of the 1st cylinder reaches TDC, read the instrument readings.
- Plunger stroke - 0.51-0.61 mm/to TDC
If there is a discrepancy, adjust it.
11. Turn the crankshaft clockwise one full revolution and repeat steps 7 through 10.
12. Loosen the four nuts securing the high-pressure pipes on the fuel injection pump side.
13. Loosen the two fuel injection pump nuts and one fuel injection pump mounting bracket bolt. (Do not loosen the nuts more than 1/4 turn).
14. Set the required plunger stroke by slightly turning the fuel injection pump body as shown in the figure.
- Plunger stroke - 0.58+0.03 mm/to TDC
If the plunger stroke is less than recommended, turn the fuel injection pump towards the engine and vice versa.
15. Tighten the fuel injection pump mounting nuts and the fuel injection pump stand mounting bolt, then repeat steps 7 through 10.
16. Remove the dial indicator and adapter.
17. Install a new gasket and tighten the distributor head bolt.
- Tightening torque - 17 Nm
18. Tighten the four nuts securing the high-pressure pipes on the fuel injection pump side.
- Tightening torque - 30 Nm
19. Install the coolant bypass hose.
20. Fill with coolant.
21. Connect the negative battery terminal.
22. Start the engine, check for coolant and fuel leaks.