A) Remove the bolt - plug from the distribution head of the injection pump.
b) Install a measuring tool to determine the stroke of the plunger and a dial indicator in the hole of the plug bolt (see picture).
2. Set the piston of the first or fourth cylinder to a position corresponding to an angle of 25°before TDC. Rotate the crankshaft pulley clockwise so that the pulley groove is at a 25°angle to the TDC pointer.
3. (Except 3L) Turn off the heating control.
A) Use a screwdriver to move the heating control lever about 20°from the stop.
b) Install a metal plate, 8.5 - 10 mm thick, between the lever and the plunger of the heating control machine.
4. Setting the injection advance angle,
A) Set the dial indicator to 0 mm.
b) Be sure to maintain the 0 mm value on the indicator while turning the crankshaft pulley through small angles clockwise and counterclockwise.
V) Slowly turn the crankshaft pulley clockwise until the pulley groove lines up with the TDC setting benchmark.
G) Measure the plunger stroke.
Plunger stroke:
- with automatic heating control device
2L, 2L-T, 3L - 0.54-0.66 mm
1KZ-T
for Europe - 0.39 - 0.43 mm
the rest - 0.58 - 0.62 mm
- without automatic heating control
2L.3L - 0.84-0.96 mm
d) Loosen the nuts of the high pressure pipes on the injection pump side (1), two bolts for fastening the injection pump to the bracket (2) and two nuts for fastening the injection pump to the timing belt cover (3).
e) Adjust the plunger stroke by slightly turning the injection pump housing.
If the stroke is less than specified, turn the pump towards the motor.
If the stroke is greater than specified, move the pump away from the engine.
and) Tighten two nuts (1) fixing the flange of the injection pump with a torque of 21 Nm. Recheck plunger travel.
Tighten the two rear support bolts (2) torque 18 Nm.
Tighten the nuts of the high pressure pipes (3) moment:
- L series - 25 N.m
- KZ series - 15 N.m
5. (Except 3L) Remove the metal plate installed between the lever and the plunger of the automatic heating control.
6. Remove the special tool and dial indicator.
Install a new gasket and bolt into the distributor head plug.
Torque
L series - 17 N.m
KZ series - 25 N.m
7. Start the engine and check for fuel leaks.