2. Drain the engine coolant.
3 Disconnect the coolant bypass hoses from the thermostat.
4. Disconnect the fuel hose from the fuel inlet tube.
5. Install the special tool and dial indicator.
- A) Remove the stub bolt with gasket from the distribution head of the injection pump.
- b) Install a special device with a dial indicator to measure the stroke of the injection pump plunger and the plug hole in the distribution head.
6. Using a screwdriver, turn the cold start assist lever counterclockwise by approximately 20°. Insert a metal spacer 8.5-10 mm thick between the cold start lever and the cold start plunger.
7. Check and adjust the injection advance angle.
- A) Set the dial indicator to "zero".
- b) Check the setting of the dial indicator by slightly turning the crankshaft pulley clockwise and counter-clockwise and make sure that the dial indicator remains on the reading "zero".
- V) Slowly turn the crankshaft pulley clockwise until the groove on the pulley lines up with the alignment mark.
- G) Measure the plunger stroke.
- Plunger stroke 0.55 - 0.61 mm
- d) Loosen the following bolts and nuts:
- (1) - the four nuts for the high-pressure fuel pipes on the injection pump side.
- (2) - a bolt of fastening of an arm of TNVD to a rack
- (3) - two nuts for fastening the injection pump to the coolant pump
- e) Adjust the plunger stroke by slightly turning the injection pump housing. If the plunger stroke is less than specified, then turn the injection pump towards the engine, if the plunger stroke is greater, deflect the injection pump from the engine.
and) Tighten the following bolts and nuts:
- (1) - two nuts securing the injection pump to the coolant pump and check the stroke of the plunger.
- Tightening torque - 18 Nm
- (2) - bracket bolt. injection pump to the rack.
- Tightening torque - 47 Nm
- (3) - four nuts for the high pressure fuel pipes.
- Tightening torque - 29 Nm
8. Remove the metal spacer.
9 Remove the special tool and dial indicator
- A) Remove the special tool and dial indicator.
- V) Install the plug bolt with a new gasket in the distributor head of the injection pump
- Tightening torque - 17 Nm
10 Reconnect the coolant bypass hoses to the cold starter thermostat
11 Connect the fuel hose to the fuel inlet pipe.
12 Fill the cooling system with coolant.
13. Start the engine and check for leaks.