Contents: Examination ⬇ Adjustment ⬇
The injection timing can be adjusted with the engine removed and installed. The adjustment on the installed engine is described below. For checking, an indicator with a corresponding adapter for screwing into the injection pump is required. Adjustment and checking must be done on a cooled engine.
Examination
1. Disconnect the negative cable from the battery.
2. Remove the air filter with the air intake sleeve.
3. Remove the PCV hose from the cylinder head and release the wiring harness from the retainer on the intake manifold.
4. Unscrew the mounting bolts and remove the intake manifold.
Intake manifold mounting bolts
5. Remove the upper timing belt cover.
6. Set the piston of the first cylinder to the TDC position (see Chapter Engines).
7. Remove the fuel lines from the injectors and the high-pressure fuel pump, for which remove the union nuts.
Do not change the shape of the pipelines.
8. Unscrew the plug from the fuel injection pump distributor housing.
Plug in the fuel injection pump distributor housing
9. Screw in an adapter instead of the plug, for example, KM-226-a and an indicator with a measuring range of 0÷3 mm).
10. Use a screwdriver to remove the cold start speed increase device from its working position.
Disabling the cold start boost device
11. Set the indicator to a position approximately 2 mm when the measuring rod touches the pump piston.
12. Turn the crankshaft counterclockwise by about 60 degrees so that the pump piston is at the bottom. At this point, the indicator shows the lowest value and does not move anymore. In this position, set the indicator to "0". Check the adjustment by slightly rotating the crankshaft in different directions. The indicator should not show a value less than 0 mm.
13. Turn the crankshaft clockwise until the TDC marks are aligned and read the indicator. Compare the indicator readings with the Specifications in Chapter Fuel, exhaust and emission control systems.
14. If the requirements of the Specifications in Chapter Fuel, exhaust and emission control systems not achieved, adjust the fuel injection pump.
Adjustment
1. Unscrew the fuel injection pump mounting nuts and the adjusting bolts on its holder.
Fastening nuts (top) and adjusting bolts (bottom) of the fuel injection pump
2. Turn the injection pump to achieve the required Specifications in Chapter Fuel, exhaust and emission control systems adjustment value (the average value from that specified in the Specifications Chapter Fuel, exhaust and emission control systems range). If the value is too high, turn the pump towards the engine; if it is underestimated, in the opposite direction.
3. After completing the adjustment, tighten the fuel injection pump mounting bolts to the cylinder head with force 25 Nm, and the fastening of the fuel injection pump holder - with force 45 Nm.
4. Remove the indicator.
5. Tighten the center plug with a new copper sealing ring with force 20 Nm.
6. Remove the screwdriver from the cold start device.
7. Connect the fuel lines to the injectors and the high-pressure fuel pump and tighten their union nuts with force 25 Nm.
8. Use a scraper to clean the surfaces of the intake manifold and cylinder head from any remaining sealant. Install a new gasket.
9. Further installation is carried out in the reverse order of dismantling the components. Tighten the fasteners with the required force.
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