TOYOTA « INDUSTRIAL EQUIPMENT RepairManual (Revised Edition) 2J,2J-T ENGINEFORWARD This repair manual describes the description, construction, trouble shooting, removal, disassembly, inspection and repair, assembly, and installation of the various components of the model 2J, 2J-T engine. As the model 2J, 2J-T engine being a diesel engine, we have emphasized in covering the details on the Fuel Injection Pump, and its related components so as to familiarize, under. stand, and maintain a thorough knowiledge of the fuel injection system for diagnosing the trouble, and for proper adjustment. The performance of the diesel engine is controlled mainly by the proper, and correct operation of the fuel injection system. The main components of the engine is similar to the gasoline engine, and we believe your Servicemen will not have any difficulty to maintain proper repair, and adjustment. The specification, and general information are the most up to date at the time of the publication, and we reserve the right to change without notice.SECTION INDEX __GROUP INDEX = [SECT “GENERAL Eo [ENGINE TUNE-l TUNE-UP | 1] [ENGINE | 2| "FUEL SYSTEM [A TYPE INJECTION i 3] FUEL SYSTEM (VE TYPE INJECTION PUMP) 9 [LUBRICATION ~—S&M/¥ INTAKE AND EXHAUST [a [ENGINE COOLING «BA ENGINE ELECTRICAL | 8] [TURBOCHARGER __ [TROUBLE SHOOTING _ Er SERVICE STANDARD SPECIFIC) ATIONS (SSTLIST) EEGENERAL Page ENGINE VIEW ................ eee ee ee 0-2 ABBREVIATION ............0.000eeeee ee ere Oo) GENERAL RULES OF SERVICING WORK ........... o- 5 ENGINE PERFORMANCE CURVES o-6 SPECIFICATIONS ....... eee eee eee eee eee oe0-2 ENGINE VIEWABBREVIATION a (2) 3) 4) (6) The foltowing abbreviat RH are used in this Manual r3 tO two mating parts or, more specifically, to the dimensions of such parts LH for lefthand. SST for special service tool Special service tools are those designed and manufactured by TOYOTA Service Department specially for use on the present vehicle, Each such tool will be indicated usually in full spelling, followed by its part number included in parentheses ( 1] STD for standard, This adjective is used to qualify dimensional values and, when so used, means that the qualified value was established in the original assembly during manufacture. OS for oversize. “Oversize” ref Piston diameter and bore diameter are an example, Some parts are available in different sizes for replacement purposes; the sizes increase in steps, starting with STO (standard) dimension and ending with the largest O/S dimension U/S for undersize. Indersize’ is similar in sense to “ ersiz: " but differs in that it refers to those parts, such as bushes and bearings, that have to be available with a smaller dimension that the STD dimension of, for instance, inside diameter GENERAL RULES OF SERVICING WORK Removal, disassembling and dismantling are common steps in servicing work. Before you remove, disassemble or dismantle any com- ponent or built-up part, observe its condi tion with respect to its position in place, the manner of association with other parts, how it is secured or held fast, etc. During the disassembling step in overhauling such as an engine, a large number of parts, large and small, come out. Set them aside in an orderly manner, identitying each part as 10 its location and orientation, so that you would have little difficulty in restoring them to their original conditions during the re-assembling step, Be systematic throughout the overhauling process. Use of liquid packing (SEAL PACKING No 5 is prescribed) is often necessary on parts subject to oil or water leakage. Be sure to have the fiquid on hand for ready use. Every bolt used in the present vehicle is covered by TOYOTA specifications. to use “specification” bolts and nuts. Tight: ening torque is specified for some fasteners 2 sure of threaded type. Use of 2 proper torque wrench is mandatory on them. Gaskets, “0 rings and like are not meant for re-use. When re-assembling, use new parts. Cost saving attained in re-using these sealing members {which were removed in disas- sembling) is imaginary. It is highty essential that genuine TOYOTA replacement parts be used whenever existing parts have to be discarded and replaced by new ones. Imitation parts are marketed widely: do not use them, or the capability of the machine may fall and a hazardous condition may creep into the vehicle. There are places in the present vehicle where the servicing work, be it an overhaul or a repair operation, is possible with special service tools (SST). Any attempt to use common tools in the place of SST’s is likely 10 result in toss of time or even in damage to ‘the parts. For the kinds of SST prescribed for the present vehicle, refer to Chapter 8: the SST’s are listed in a table0-8 ENGINE PERFORMANCE CURVES (A TYPE INJECTION PUMP) Shaft torque Ps Output horsepower é Output horsepower Fuel consumption 1000 1500 2000 2500 3000 Engine revolution ¢.p.m. 5 § 14* Shaft torque 12 8 8 Fuel consumption 9/PS-h Fig. 0-4 25 Engi Performance Curves (FDT25 Vehicles) wt Fig. 05 24 Engine Performance Curves (TD20, 25 Vehicles! ~10-ENGINE PERFORMANCE CURVES ( VE TYPE INJECTION PUMP) 23 ton vehicle w= = 11,75 :0n vehicle ‘Shafs torque 418 att torque kom Shaft output Shaft output PS a/PSh Fuel consumption rate 8 Fuel consumption rate 4000 1500 2000 2500 Engine revalution rpm Fig, 0-6 24 Engine Performance Curves € 2 § 03 a : 72000 Engine revotution rpm Fig. 0-7 2U-T Engine Performance Curves “Ne0-8 SPECIFICATIONS Engine proper Model designation 2 QT lanufacture a a TOYOTA ype Water-cooled. in-line 4 cylinders, diesel engine, | Cycle —_ 4-stroke cycle Combustion chamber Swirle type Valve location | Oven head Cylinder liner Dry type Bore and stroke 88 mm and 102 mm (3 1/2” and 4”) | Piston displacement 2481 ce (151 cu-in) ‘Compression ratio 205 ‘Compression pressure at 260 rom 27 kgler 44/2200 PS/ram 1.0 = 1.75 TON aaa — 41/2200 HPiipm || | ——— | _ 50/2500 PS/rem 60/2400 PS/rom 20-25 TON _— 47/2500 HP/rom | 86/2400 HP/rpm 2.78 — 3.0 TON 50/2500 PS/ram 60/2400 PS/rpm | 47/2500 HP /rpm 56/2400 HP/rpm 55/2800 PS/rom FOT25 —— - [7 52/2800 HP/rom | | : |. 50/2700 PS/rpm_| an ec |TD20, 25 I bee output 47/2700 HP/rpm | | 32/2500 PS/rom _ |soKe 30/2500 HP/rpm 50/2500 PS/rom SDK8 - 47/2500 HP/-pm s07 50/2500 PS/rpm 28010, 12 47/2500 HP/rpm i 44/2200 PS/rpm \uor2 OO ae | 41/2200 HP/rpm | == | [J 14572000 kg miro _——— 1.0=1.75 TON | | — | 10072000 feibirom [ Rated 2 __———__ | 14.5/2200 ka-m/rom | 18.0/2000 kg-m/rom torque |20-25 TON 5 — 100/200 feib/rom | 125/200 fr-b/rpm SS 14.5/2200 kg-m: 18.0/2000 kg-m/rpm 2.75 -3.0 TON 100/220 f-lo/rom 125/200 ftlb/rpm1451/2200 kg-m/rpm FDT25 100/200 felb/rom 14/2400 kg-mit 1020, 25 feo] 7101/2400 frb/rpm | 10/2000 kg-m/rpm SOK6 = Rated 70/2000 ft-lb/rom torque 14.5/2200 kg-mirpm { SDKB 10/2200 f-lo/rom i ‘$07 14.5/2200 kg-m/rpm | 28010, 12 10/2200 ft-lb/rpm 14.5/2000 kg-m/rem s012 100/200 ft-tb/rpm Min, full-load fuel 190 g/PS-hr 197 g/PShr 190 g/PS-hr consumption at 1600 rpm (at 1600 rom) (at 1000 rpm) {at 1000 rpm) Engine dimensions 713x565x689 mm | 670x560x645 mm | 670x560x 700 mm (LxWxH) (28.5"x22.6""x27.6") | (26.4°°x22.0" x25.4")| (26.4°°x22.0"x27.6") 42 ke 1 Engine service weight feeder 214 kg (471 Ib} 217 kg (478 Ib) Material of piston Aluminum alloy Number of | Compression ring 2 3 2 piston ring [Oirring 7 7 Valve timing Intake Open Ati6® BTDC valve Close At 44° ABDC Exhaust | Open At 52° BBDC vaive Close Ala? ATDC Valve clearance Intake valve ~ 0.20 mm {0.0078") (hot) Exhaust valve 0.36 mm 10.0141”) thot) No-load engine rom 660 Fuel ignition By heat of fuelair mixture compression Fuel injection timing 13° (static) BTOC oP TOC oP? TOC ‘Order of fuel injection 7-2-4-3 Injection pump Tyee Bosch A tye Bosch VE type Bosch VE type ‘Maker NiPPONDENSO - Plunger diameter 9mm (0.35") 9mm (0.35") Cam lift 2.2mm (0.087") | 2.2mm (0.087") ~13-0-10 Governor Type Vacuum I Mechanical (all speed) Maker NIPPONDENSO Injection timer Type Centrifugal Hydraulic type Maker NIPPONDENSO| Injection nozzle Nozzle holder mounting Serew-in Nozzie type Throttle type Number of injection orifice 1 {one) Orifice diameter Timm Injection pressure 118 — 125 kg/em? (1635 — 1778 psi) Preheating plugs Type Seized type Maker NIPPONDENSO Voltage-current 20.5V-4.0~ 5.64 Fuel pump Z Type Plunger type Maker NIPPONDENSO : Lubricating System Type of lubrication Full pressure forced-feed lubrication Lube oii pump Gear type Lube oil filtration By paper-element full-flow filter Lubrication system oil capacity’ 7.0 @ (1.85 US gal) Cooling system Type of cooling Water cooling by belt-driven water pump for recirculation Cooling system capacity 10 & (2.6 US gal) Water pump. Centrifugal type | Thermostat — Wax type : | Charging generator z Type Alternator Maker - NIPPONDENSO Voltage 7 2aVv a Maximum output 16A at 28V Type of regulator unit Titril type Starting motor Type OC motor complete with magnet-actuated clutch and pinion Maker NIPPONDENSO Voltage-output 2aV—45V -14—ENGINE TUNE-UP Page V-BELT INSPECTION AND ADJUSTMENT ........... 1-2 VALVE CLEARANCE ADJUSTMENT ..............4 1-2 COMPRESSION PRESSURE INSPECTION 1-3 INJECTION NOZZLE INSPECTION AND. ADJUSTMENT 2.0... 0.02 cee eee cece eee eee ee 1-4 INJECTION TIMING INSPECTION AND ADJUSTMENT 2.0.00... cece eee cece ee ence eee . 1-5 IDLING RPM AND NO-LOAD MAXIMUM RPM. ADJUSTMENT 2.0... cece cece eee e teens eee enes 1-71-2 V-BELT INSPECTION AND ADJUSTMENT Standard VALVE CLEARANCE ADJUSTMENT | ai] cE ea a EX I Fig. 1-4 Adjusting the Vaive ClCOMPRESSION PRESSURE INSPECTION (VE PUMP) Note: Use the same number of compression strokes for each pression if ten com: sary to obtain the 1 cylin the same number of inders, es for other cy Fig, 1-8 Measuring the Compression Pressure1-4 INJECTION NOZZLE INSPECTION AND ADJUSTMENT 1. Inspection and adjustr sure (1) Measure the injection pressure with the nozzle tester Standar of injection pres. 110 — 125 kg/cm? (1564 — 1777 psi) [reused nozzte} Note: © Repidly move the tester lever to cause in- jection a few times to blow off the carbon deposit at the nozzle orifice Slowly push the tester lever to raise the pressure. Read the pressure at the moment when it changes from rising to sudden fall ° {2} If the pressure is outside the standard, select the proper washer at the top end of the spring for adjustme: Standard: 115 — 125 kg/cm? (1636 — 1777 psi) {at adjustment) Reference: © 20 types of washers are provided in 0.05 mm (0,002") steps in the range of 1.00 — 1.95 mm (0.039 - 0.077") © The injection pressure changes by about 5 kg/cm? (71 psi) for each 0.05 mm (0.002) change in the washer thickness. 2, Oit tighteness check at valve seat (1) Slowly push the tester lever to raise the pressure to a level 10 ~ 20 kg/cm? (142 — 284 psi) lower than the specified ure. Hold the pressure for O seconds and make sure that no fuel is leaking from the nozzle (2) If the fuel is leaking, recheck the nozzle sassemibly and cleaning or + le with a new one 3. Nozzle opening and spray pattern (1) After setting to the specified injection pressure, pump. 60 strokes per minute by hand. The nozzle tester lever 18 shall discharge at any stroke in this range. (2) Check the spray pattern in discharged state. {See the figure at right) (3) If Gefective recheck the nozzle after disassembly and cleaning or reptace the nozzle with a new one, Washer | ‘ | Good Defective | 11 Inspecting Ou tigntnes at the Valve Seat || i | i {| \ :INJECTION TIMING INSPECTION AND ADJUSTMENT (VE PUMP) 1. Adju No.1 cylinder to the TOC the dial gauge ndard ndtion pump mounting et unde (a) tha injection timing pump body ured value in the standard, move the pump body in direction A, he measured value in above the standard, move the body in direction B. isbs ghten the injection pumo « and the br ne loosened 0: Caution © Use a new copper washer © Carefully prevent entrance of dirt o} foreign matters Fig. 1-18 Adjusting the Injection TimingIDLING PRM AND NO-LOAD MAXIMUM ADJUSTMENT (VE PUMP)Fig. 1-25 uring the Engine Speed at Full RefietENGINE2-2 COMPONENTS it Filer cap Cylinder head cover Head cover gasket Push rod cover gasket Push rod cover Cylinder liner shim Git tavel gauge Cylinder bioes sub-assy Guide support Cylinder liner Gylinder Read assy Exhaust bushing 13, 14 15, 7. 18, 19, 20. 21 2 23 24, Intake bushing Deflector No. 7 Tube Rear plate gasket Head rear plate Ring pin Oil level gauge guide Cylinder head gasket il pan gasket Gasket Pug Oil pan sub-assy Fig. 21 Engine Assembly Components No.1Piston sub-assy Piston ring set Crankshaft bearing set Connecting rod bearing set Bushing Connecting rod sub-assy Thrust plate Idle gear Idle gear shaft Crankshaft Grankshatt pulley Timing gear Key Fig. 22 14, 15 16. 17, 18, 19, 20. 21 22 23. 24 25 26. Engine Assembly Components No.2 33 22 24, 28 23 30-4 ‘Thrust washer Lock screw Valve rocker shatt Valve rocker support No. Valve rocker arm Nut Valve rocker arm Valve adjusting screw Comprastion spring Valve rocker support No. Valve rocker support No. Valve rocker support No. Push rod 2B 27 28, 29, 30. 3 32 34 35. 36 37 38, 39, Valve lifter Spring retainer lock Spring retainer Seal Compression spring Exhaust valve Timing gear Key Camshaft Coltar Bearing Thrust place Camshaft bearing set2-4 DISASSEMBLY AND INSTALLATION Tools needed (1) Wrench, nozzle holder, 09268-48012 (2) Puller, crankshaft pulley, 09213- 31021 {3) Remover, combustion chamber 09208-48010 {4} Remover/replacer, piston pin, 09221— 46010 (5) Engine hanger 09010-201 10-71 (6) Engine hanger 09020-201 10-71 (7) Femover/replacer, main drive shaft 09210-20170-71 Note Disassemble only to the extent necessary for the purpose. Before disassembly, have a clear idea of how and why of the cause of the trouble and determine what parts to be removed and what parts are not 1, Remove the engine together with the trans mission and clutch 2. Remove the main drive SST (09210-20170-71). 3 utch cover and clutch disc 4 ter, and separate the engine using. 5 2 flywheel, and remove the rear {only on vehible with torqu 6. ting pins, Set up the eng the work stand SST (09010-20110-71) SST (09020-201 10-71) 7. Remove the bo! 1g the oil level gauge guide, Disconnect exhaust manifold. Note Loosen the nuts sequentisily, loosening each nut just little at a time and shifting your wrench across i order to avois distortion, 8. Take down alternator, oil filter and ail be Note When removing any fuelsystem part, make sure that Gust oF dirt will not go into the system. Fig. 28 Injection Pump Removal 11. Disconnect injection pipes. 12. Disconnect link rod and hose, and remove intake manifold,13. Detach over-injection magnet and take down Note: For vehicles with a VE-type injection pump, see Section 4, "VE-type Injection Puma”. Disc ozzle leakage pipek, and re cover packing rings, Using the SST (09268-46012), remove each nozzle hold 16. At each cylinder, loosen glow plug connect ing nut, disconnect the plug connector, and remove plug. t bypass hose, and remove water ¢ housing ch the pulley and take down water Linder head caver. Remove val ly. 20. Pull off pushrods, remove pushrod cover and draw each valve lifter head bolts by hows the loo% Ferri ening seque @ bolts ar to remove oil 23. Using the SST shaft auliey. 0211, remove 24, Remove timing gear cover Notes: 1, Automatic out as attached to the cover. Handle the cover éarefully 50 as not to let the timer fall off 2. To separate timer from cover, heat the cover in 4a bath of hot oil until the timer slips out whan pulled by hand, Normally it is not necessary to hheat to above 60°C. thrust pla assembly. Be careful not to damage the camshatt besring 26. Remove the set bolt on idle gear. Take off thrust plate, idle gear and idle gear sl 27. Remove timing gear case. =— 0921331021 Fig. 2-8 Crankshaft Pulley Remove Fig. 2-9. Camshaft Removalnbbly, a5 show 1. Ie may be necessary to decarbon the cylinder bore in order to allow the piston to come out 2. After taking out each piston assembly, be sure to haw its connecting rod cap attached to the connecting rod. This is for making sure that each piston assembly be handled as a set, Do not swap parts between sets 3. Mark each piston assembly, identifying the cylinder from which the assembly was removed 29. bly. as follows pistor move snap ring, and force piston in out by using the SST 019}, The piston is to be shown in figure, v ton heated to anywhere be tween 50 and 60°C by means of the piston heater 31 out cransshatt Note fe bearing shells of crankshaft bearings are to be restored to their original positions at the time o! reassembling, So, mark the shells for easy identification 32. Using she SST (09: combustion chamber 48010}, remove each Note Handle the chamber carefully so a5 not to damage their blow holes. 33. move valves, Far spring comoressor is to be used. T! cated as 1, 2, 3, come off a Fig. 2-11 Piston Pin Removat TK 08208-2801 0 “ngInspection and Repair Notes 1, Before inspection, have all parts washed clean and made free of dust, grease, carbon and scale formations, 2. Clear a oil compressed air 3. To decarbon the cylinder head and valves, holes and ways by directing SST's and Instrument Needed jover, valve guide bush. jolacer,, reat i seal, 8) Remover, connecting rod 40011 Puller, crankshaft 09268-46012 straight, bore gauge Cylinder Head 1. Visually inspect the h face damage. If any sign of cracking is noted conduct @ magnetic particle te: penetrant test to e extent of the crack in order to see whether the head can be re-used by repairing or not 2. Using the straight edge and thickness gauge, ck the gasketed surface of the cylinder for warpage, as shown in Figure, If for sur: t or a dye the warpage is found to exceed the limit, repair the surface by griding. A surface grinder should. be used for this purpose, Limit of warpage: 0.15 mm {0.008} 1. Check the warpage at 6 straight edge positions fone along each edge and two diagonals. 2. combustion chambers ate left in place, place the straight edge off each cnamoer position ‘The thickness gausge should nat be used there 3. Check the mani head for warpag: thickness gauge. If the surface is waroed fond the limit, the head must be repaired or replaced. (Fig 1-17) Limit of warpage: 0.2 mm (0,0078") exercise the common precaustion :0 as not to amage critical surfaces. Do not use any srarp. cutting toot 4, Assemblies and subassemblies must be handled as sets. Have them set aside manner, with proper identifying marks. Fig. 2:15 Measuring Head Lowe Surface Fig, 2:16 Measuring Manifold tnstalling Surtace2-8 Valves 1. Inspect intake and exhaust valves visually for wear, evidence of burning or ularly at the stem and head portions. An excessively worn, de formed or burnt valve must be replaced 2, A valve not meeting the following minimum, requirement on thickness of head margin must be replaced Limit on head margin: 0.9 mm (0.035"") (intake valve) 1.0 mm (0.039"} (exhaust valve) 3. Repai end he valve if its face (seating) or stem 2 cont er arm) is exessively worn, nicked or otherwise damaged, as shown in figure. Prescribed face angle: 45 degrees Repair limit on stem end: 0.5 mm (0.019") ng the Valve Guide Bushes bush, If this ct reduce it to the standard value by repla valve or the bush, or both Stem-to-bush clearance Limit: 0.10 mm {0,0039") (intake valve) 0,12 mm (0,0047") {exhaust valve} Standard: 0,02 ~ 0,08 mm rance is noted to exceed 1 (0.0078 ~ 0.0024") {intake valve), 0,04 ~ 0.08 mm (0.0016 ~ 0,031") (exhaust valve] Note: The clearance is to be computed with two diameter readings: stem diameter and guide bore digmeter. Valve Guide Bush Replacement 1. Using the SST (09201-60011), force the guide bush out by driving as Figure. The bush comes out a surface of the cylinder head. 2, Install the replacement bush by using the same SST. The bush is to be driven in from top side, that is, in the same direction as removing. Ream the bush bore as necessary Protrusion of bush: 17 mm (0.67") {both intake and exhaust valves) Note Bushes are in two lengths, S6 mm (2.20") {far intake valvel end 60 mm (2,36") (for exhaust valve) Fig. 2.17 Measuring Valve Head Thickness Fig. 2-18 Measuring Valve Guide Bushing To Stem Clearance Fig. 2:20. Valve Guide Bushing Replace:Valve Seats The valve seat is to be inspected for signs of uneven contact and damage. A damaged seat or 3 seat exhibiting uneven contact can be repaired for reuse if the malcondition is not advanced too far Notes 1. Ifa seat is found to need repair, check the worn condition of the guide bush first, Correct the bush and then repair the seat. 2. Use the valve seat cutter or grinder to re-face the contacting portion of the seat to obtain the Gimension (with) shown in figure, After cutting or grinding, lap the contacting face with the valve, using a lapping compound, and check for full face contact by using red lead How to use vaive seat cutter The commonest cutting method is as fotlows 1, After re-facing the seat, check the angles (1) (2) and (3), shown in figure, and write Down the chacked angles for reference, 2. Operate the cutter to obtain the 45° angle first, next the 30° angle and the 60° angle last, The fast cutting is to be controlled carefully in order to obtain the prescribed width of contacting face Wide of contacting face 1.3 ~ 1.6 mm (0.081 ~ 0,063") (intake valve seat) 1.3 ~ 1.8 mm (0.051 ~ 0.063") (exhaust vaive seat} 3. The 45° angle 1ould be located at the middle of the beveled part of the seat. To meet this requirement, 30° and 60° cutting operations must be adjusted carefully, ce Note If the contact pattern is (ow, when checked initially, reface only with 30° and 45° cutters. Where the pattern is noted to be high, use only the 60° and 45° 1.3 ~1.8 mm (0.051 ~ O.08s" Fig, 2:21 Valve Seat Contacting Width Fig, 2-23. Seat Cutting Sequence | J concing soson eae2-10 Compression Spring must be repiaced. Limit on squareness: 2.0 mm {0.078") 2. Using the spring tester, check each spring for elastic strength, Springs not meeting the following specification values must be re. placed. in | Asinstalied | Instaed Load feeienath | tength | Standard 45.1 mm 40.0 mm 21.7 kg ina) | asi" | (47.8 tbs) Valve Rocker Arms and Rocker Shaft 1. Clear oil holes by directing compressed air to each hole. Make sure that the holes are not clogged. 2. Inspect the arms and shaft for excessive we: and damage, Repair or replaces as necessary. Note The pushing face of a rocker arm, bearing on the value stem may be found to present a stenped surface due to wesr. Such 3 face can be repaired by grinding with an oil stone. 3. Check the clearance between each arm and. rocker shaft. Limiting values ass this clearance are given below, Where the limiting value of the clearance is exceeded, replacement is necessary Limit on arm bore diameter 18,60 mm (0.73") Limit on arm-to-sha' 0,1 mm (0,0030"} Standard arm-to-shatt clearance 0.01 ~ 0.05 mm {0.00039 ~ 90,0019") Valve Lifters 1 each lifter and replace it if it is found in excessively worn or badly damaged condition, Note If the face of the litter riding on the cam is found with scratch or groove marks, inspect the cam too. er (ST 22.19 mm (0,872 ~ 0.873 ran en Limit 0.1 mm (0,0039") Specified 0.01 ~ 0,05 mr 39 ~ 09,0019 Fig. 2-28 Measuring Lifter Oil Clearance2-11 Camshaft 1. Inspact the camshaft for straightness and journal parts, A distorted 2 camshaft with its journals excessively worn or damaged must be re paired or replaced. Limit on_ straightness 0.04 mm (0.0016") Limit on taper: 0,01 mm (0.00039 {deflection} Nee maximum Straightness is half the value of deflection read on 2 tor used in the manner shown in Fig, 2 rust clearance on camshaft, as shown in figure. If the limit is found to be exceeded, replace the thrust plate to reduce the clearance to the standard value Thrust clearance limit:0.3 mm (0.012") Standard clearance:0,06 ~ 0.13 mm (0,0024 ~0,005 1" When taking measurement on the thrust clearance, make sure that the thrust plate and timing gear are secured to the shaft by tightening to the prescribed Note: torque value. Tightening torque specification; 300 ~ 450 ka.em sneering (217 S228 te) 3. Chack the cam height. Replace the camshaft f the height of any cam js less than tt limiting valve, mit on cam height: 38,98 mm (1.559) {Intake} 38,91 mm (1.586") Camshaft Timing Gears (Exhaust) 1, Inspect timing gears for fit on respective condition of the gear teeth, etc. A or damaged gear must be shafts, badly worn replaced heck the back lash on each gear relative to crankshaft timing gear. Where the backlash is in excess of the limiting value, both the gear and the crankshaft timing gear_m placed. Limit on backlash: 0.3 mm (0,012") ndard backlash: 0,10 mm {0,0039") Camshaft Timing Gear Replacement 1. Remove bolt and plate. 2. Use a press to force the timing gear off the shaft end, applying the push to the shaft end and supporting the thrust place, as shown in figure, When installing the replacement timing gear, make sure that the thrust plate takes its Position so that its oil way and TOYOTA mark come on the front side, Prass the gear e 33 Thrust Clearance Inspection Fig, 2:30 Fig. 232 Camshaft Timing Gear Replacement2-12 onto the \d by applying the push to the end ft, a5 shown. 4, Tighten the securing bolt to the prescribed torque vatue. 300~480 k Idle Gear 21,7 ~ 32.5 ft-lb) 1. Insp and shaft for the fit of , gear tooth damage and wear, 2 Following minimum met or if the gear or conditions ndard on gear ID: 50,00 ~ 50.03 mm (2.0~ 2.0012" Standard on shaft OD: 49. a 197 ~ 1.998") Gear-to-shatt clearance Limit on clearance: 0.30 mm (0.012") Standard clearance: 0.04~ 0.09 mm Thrust clearance {0.0016 ~ 0.0035") Limit on clearance: 0.35 mm (0.014") Standard clearance: 0,08 ~ 0.18 mm {0.0031 ~ 0.0071") Check the backiash between idle gear and crankshaft timing gear. If the backlash eded, replace both idle gear crankshaft gesr Limit on backlash: 0,30 mm (0,012"1 ‘Standard backlash: 0.10 mm (0,0039") Power Take-Off (P.T.0) Gear 1, Inspect the P.T.O, gears, and r bearing or worn, sex and ing portion or teeth are damaged 2. Measure the backlash between the camshaft timing gear, and replace if it exceeds the mit. Backlash limit: 0,30 mm (0,012"} Specified backlash: 0.10 mm (0,0039") Input Shaft Front Bearing Replacement 1. Using the SST bearing from the 2, The replacement bearing is to be driven into position by using the Flysheel 1, Inspect the face of flywheel contact with clutch di ut and ssary damage. Repair or if the ring gear rwiise damaged cracked or Note The ring gear is co be removed in hot state Iby heating the gear) by means of 08303-25011 fi 1g. 2:36 Oil Seats InstallationOil Seal (Type T) Replacement (for crankshaft) Drive the oif seal toward remove it ones | 2. To install she replacement oil seal, use the | SST (09223—4¢ | 11) for front seal and the 10} for rear seal, = 09: ‘ons, Piston Pins and Rings Mark iaaicating Nowe Since the messured values of 24-7 differ from those nena the piston pin shown below, sae the Appendix, “Servicing Standard | Meeviinder cumber——-p oa Specifications | Mark indicating the outer diameter or the piston 1. Inspect piston ring grooves of each 0 Fig, 2:37 Piston Stamped Markings, wear, damage and signs of any ‘alcondition. Replacement may be ni ry depending on the resui his inspe jon The fit of piston pin in piston must be such that, whan the piston is heated to 50 ~ 60°C, the pin will smoothly go into the piston under thumb pressure, 2, Make sure to use rings of the same size as that of the piston. 2 sure: on ring end gap and side on ring in the groove. Aing should be governed by the 25 Note red with the ring located vylinder bore, as shown in The end gap is to be at the lower part of figure. 3 Standard ard 939 es are found in the c When installing the replacement connecting rod, be sure to provid2 @ permanent mark on it to indicate Fig. 2-40 Measuring Connecting Rod for Bead the numbar of the cylinder, to wirod aligner, check the face contac: Limit on straightness: 0.05, {0.0019} for each 100 n Limit on twist: 0.15 mm (0.005 for each 100 mm 3.94") Connecting Rod Bush Replacement fas wore oF & Use a press and T (09222. imit on oil clearance: 0.05 mm {0.0019") doi clearance: 0,004~0.012 mm (0.00016 ~6.00047") Note: When pressing the bush into the small end, make sure that the oil notes align within the small end. 2. After pressing in the bush. ream or hone the bush the diameter meeting that of its ston pin, A reamer or 2 pin hale honing sed machine should ndard oil cle: 0.004 ~ 0.012 mm {0.00016 ~ 9.00047") Note The fit of pin in bush should be such that, at room Kemperature, the pin wet with engine oi! will smoothly go into the bush when given thumb pressure. Connecting Rod Bearing 1, Inspect each bearing for surface scaling burning, signs of fusing and conta ace the bearing as necessary tern 2. Using the press gauge, check the oil c prea Cap tightening torque: Note The bearing removedmust not be reworked for reuse. No shim adjustment i allowed. Bearings appearing to need repair must be replaced by new Limit on oil clearan: Standard oi! ry if the che limit, With to obtain a crankshaft is replaced, STO size 0822266010 Fig. 2-43 Measuring Oil Clearance 2. If the standard il clearance doss not result even with an U'S 0.08 bearing, use an U'S 0.25 aller bearing and grind the erankpia to 3 new diameter that will produce the d2siedCrankshaft thrust Washer 1. Push the cranks rea imit, reo lacement washer, be sur ames on tha thtust-rzeaivin ate for straightness, and2-16 Crankshaft Bearing 1. Inspect burning Re sealing, pattern, bearing igns of fusing and cont: 2 bearing a5 necessary. 2. Using the shown in figur check the oil bearing and its journal. Tighten the cap to a 980 ~ 1120 k (70.8 — $0.9 feb) torque, Note Crankshaft bearings are not meant for repair by machining or for shim adjustment. If any bearing appears 10 nead such a remedy, replace it by a new Limit on 0 Standard 0: 3 Note Use STD size bearings on a new crankshaft. If 3 proper oil clearance fails to be produced sven an UIS 0,05 Dearing, reduce the journal diameter Dy grinding and use an U/S 0.28 or emaliar basring Camshaft Bearings 1. Inspect each bearing burning, signs of Defective bearings must be rex 2. Check the In Dy bearing 1D and journal diameter and co puting the difference. Replace the bear the limit is exceeded Limit on oil clearance: 0,10 mm (0,0039"") Standard oil clesrance 0.03 ~ 0.07 mm {0.0012 ~ 0.0028") for 9 and cai oil measurin Note: The journal must be reground if a WIS 0.125 or smaller bearing nas to be used on it. Fig. 247 Measuring Crankshaft Ol Clearance Bearing size | Journal diameter (finished) STD | 98 ~ 70.00 (2 789~ 2. UIS 0.05 73 ~ 69.75 mm 2.745 2.748") 69.48 ~ 69.50 mm (2,735 ~ 2.736") 69.23 ~ 69.25 mm Camshaft bearing sizes and journal diameters (finishad) Bearing | _ Journal_diametar_mm tin size No. 1 journal [No.2 journal No. 3 journal jo. 2 journal STO IS 0.125 UiS 0.252-17 Camshaft Bearing Replacemeny by devi ed aliows the bearings to be ved with the use of the $S (09215-00700) Notes: 1. The camshaft bearings are sized increasingly larger in ID, starting from rear side toward front side, and marked with numbers 1 through 4, No.1 and No bearings are additionally marked with an arrow pointing to front side 2. When installing the replacement bearings, make sure that each bearing is correctly oriented ang with its oll hole meeting that provided fock. cylinder 2, The plug x00 is to nd (No. 4) to t 1 into position with a press, and for Cylinder Block 1. Visually in: the block for cracks or 2 the block is found with king, determina the extent of tor glace other dam signs of running a dye oenetrant Repair or on the result of the le te agnetic particl block, depend test. Check the fed surface of the cylinder block warpage, as shown in and repair or replace the block if the limit coeda @:0.10 mm (0.003 on warpage is ex: Limit on w Note: To repair the and work on the surface wi removed keted surface, use a surface grinder alleylingar liners flanged portion of s proud of the gasketed mount (standard value) 0.03~0.12 mm (0.0012 ~ 0,004 Note Mf the protrusion is not enough, adjust it by shimming, Shims for this purpose are available in 019) and 0.10 mm two thicknesses: 0.05 (0. 70,0039". ail holes drilled in the 4. Mal block are clear Cylinder Bore Diameter Measurement Use the cylinder take bor ments, Thi places Fig. 2 Fig. 2-51 Measuring Liner Protrusion ay ‘Thrust direction ‘About 18 mm 10.6")2-18 block must be replaced or may be re-used without any re-working, Limit on wear: 0.60 mm (0.024") Standard bore diameter: $8.00~88.03 mm Notes (3.46 ~ 0.47") 1. If any of the four cylinders needs reboring, Cylinder Boring Take diameter readings on the piston at its skirt {thrust surface). The value of diameter based on these readings is the reference value to which the cylinder is t0 be cebored in such a way a5 to provide the standard cylinder-to-piston clearance. Standard clearance between cylinder and piston 0.11~0.13 mm (0,0043 ~ 0.0051") Piston diameter STO: 87.88~87.91 mm (3.45 — 3.46") cebore the other cylinders too, and replace al! pistons by 01S 1.00 aistons. 2. Where the wear limit is closely approsched but not exceeded, reboring may not be required. Ia such a case, removing the ridge at the top portion of the bore by means of 3 ridge reamer may qualify the block for re-use. O/SNot | 88.88 ~ 88.69 19.5882~3.55057 O/SNo2 | a9.89~88.90 3.5556 ~a5567) OISNo3 | 8890~88.91 G.a80~ 35560) Note: a The top end of the eylinder tiner is proud of the So gasketed surface of the cylinder block by about 0.2 mm (0,0078"), For this reason, 20,2 mm (0.0078"") thickness gauge must be interposed under the boring machine. Piston Clearance Measurement The simplified method of checking the piston clearance is based on the use of a thickness gauge. Insert the piston upside down into the cylinder, with 3.0.1 mm (0.0039") thickness gauge inserted in between, Susgend the gauge from 3 spring scale, as shown in figure. The clearance is proper if the thickness gauge comes out with some resistance, a5 noted on the scéle, which should be within the range indicated below Thickness gauge for testing the clearance: 0.1 mm Fig, 2:54 Measuring Piston Clearance Note The temperature of the cylinder tines will be up upon boring, Wait for the liner to cool off before inserting the piston for checking the clearance (0.0039") Resistance of the gauge to the pull: 0.8 ~ 1.2 kg (1.76 ~ 2.64 Ibs) Liner OD and interference Liner Liner hole diar | Liner outside diameter | interference nari ing mn Cin} | mit in) : nin tint Har 93,000 ~ 93,0175 | | 9.0375 ~ 0.075 1 ~ 3,662) IL | 9.00147 ~ 9.00295 93.0175 ~ 93.035 | | 9.040~ 0.0775 (3.862 ~ 3.653) I | :9.0016 ~'9.0030) 40 —2-19 Cylinder Liner Replacement Cylinder liners are to be replaced when they are found in badly damaged condition or when the ore has been worn down so much that the larg} O/S 1.00 piston produces a greater pist clearance than is prescribed. The method of replacing a lin follows 1. Draw sst (09218-46010) and a press, as shown in igu 2. Bear in ming be instalied with an that the replacement liner is to terference fit, Th cified, Select are two kinds of s 5 ner liner with respect to OD, differentiated by letter n 025 tos) inserting the liner he gasketed 0.012) to ner in pl diameter necessary on. Installation No} Have all parts thoroughly cleaned before reassembly 2. Just before installing a sliding or rotating part, bbe sure to apoly engine oil to it. 3, Gaskets, “0” rings and similar parts eemovad in disassembly should not be re-used but be replaced by new anes, 4. Use the liquid packing (sealing compound No. 5) wherever necessary to ensure water-tight or Dil tight joint 5. While the re-assembly work isin progress, check: cil clearances. and thrust clearanc: Re-assembling Pistons 1, Heat the he small end of ke sure that the ror connecting rod. marks “Fon piston and rod are on the same side, 2. Fit the snap rings 3 HI piston rings, as follows (1) Insert the of ring expander into the 0) Fig, 2-58 Line Diameter Code & Block Bore Dimension Code Locations senuantistly, each time making sure that the prescribed clearance is available 6. Be sure to discriminate che bolts, nuts and washers in eegard to kind, and to adhere ro the ng torque specifications. Those stud un into and extending from from aluminum alloy parts require special care for avoiding overtorauing 7. Do not disturd the combinations or parts, or sets. This applies particularly to bearings and pistons. Recheck the parts by referring to identification marks given to each during disassembly Fig. 2:57 Assembling Piston Compor2 ¢ing onto the piston, The oil ring goes in first, followed by the compression rings No, 3, No. 2 and No.1 Notes: 1. Position the oil ring expander in such @ way that its joint portion comes on the side opposite to the ring end gap, 2. Each piston cing is marked by punching to indicate its ring number and code. The punched face comes on the top side, with the cing fitted in place on the piston held erect. Cylinder Head Re-Assembly 1. Insert valve (5) into the head, and set (3) in place 2. Instalt spring (4), retainer (2) and, insta fock {1) by using the spring compressor. 3. Install the combustion chamber, and check to be sure that the chamber in piace somewhat proud of the gasketed surface of the head. The amount of this protrusion spe Amount of combustion chamber protrusion 0 ~0.1 mm (0~ 0,003") Note Drive the cumbustion chamber into the head, with the locating pin properly indexed to the noxch. Use a wooden mallet or a soft-metal hammer. Rocker Shaft Re-Assembly 1, Mount rocker rocker shaft. Secure the support b: ing its lock bo! Note The rocker shaft has oi! downward ipport No. 1 (1) on the valve tighten holes. Point these hole: Install rocker arm No, 2 (2) and spring, shown in fig Install the and springs. last support to is support No. similarty Note There are two kinds of rocker arms; one for No.t and No.3 and the other for No, 2 and No. 4. Be sur to discriminate the arms for their cylinders | i | | i | 0— 0.0039" L 00.1 mm | ig. 2-59 Assembling Combustion Chamber No classification mark With classification mark Fig, 260 Assembling Valve Rocker Shaft Casticatin mark | for evliners oa) & 3 | uCrankshaft Re-Assembly he cylinder block Notes: 1. Make sure that the oil nolas through the bearings and block are clean and cleat. 2, Bear in mind that the bearing half on the front J has two oil holes whereas the other haives have one oil hole ted halves 01 crankshaft on the 2. Apply engine oi! to th he block, and rest bearing: shown ipper thrust Note: The washer has oilways. Its face with the oil ways comes on the side receiving thrust fromerankshatt. tightening 1, Each bearing cap has an arrow mark, Point the arrow t0 the front end, Make sure that the caps in place are consecutively numbered, 1 through 2. The center bearing cap and the Lower washer form a combination. Be sure to install this cap. together with the washer. 3. The caps are to be tightened in two or three: eps, and sequentially in the order of Nos. 3, 4, 2, § and 1 for each step. After each tighten: ing, make sure that the erankshaft is capable of smooth rotation when turned by hand. 4 Before running in the bolts for securing the bearing caps. apply engine oil to their threaded portions and to the underside of each bolt head. Be sure and others is not disturaed and that the assembly is emoved 1at each set of piston, rings, connecting rod restored to the cylinder, from in disassembly ig. 2.68 Direction Piston Fling Gap End6 Build on the crankpin by securing the bearin a9. Before r apply engine otf to Be sure t0 the right down the hex ni underside of each nut Tightening torque: 650~750 kg-cm (46,.9~54.2 fib) 7. Install the T-tyge oil seal for sealing at the rear end of crankshaft, This sea fitted to the cylinder retainer. A gas and the seal Note Lightly coat the lip portion of the oil seai with MP grease before fitting it to the cylinder block Timing Gear Train Re-Assembly Note The re-assembly work is 10 be carried out with the crankshaft brought to the position where No. 1 piston is at the top dead center on the comaression seroke, 1. Fit the gasket to the cylinder block, and secure the timing gear case in place. 2, Install the idle gear shaft and id plate, in that with the tim the end face of idte gear accurately indexed to the mark {11 on the erank gear. T the securing bolts to the fotlowing :or Tighteningtimer drive gear over in piace Notes 7 1. The timing gear cover must be at 60°C just before it ss inscailed. Heat the cover in a bath of heated 0) 2. Apply MP grease (1) lightly to the fitting portion of the bearing. 7, Verity the insialie tion of the timer under the timing gear caver by giving nocks to the part not hit 120 aia injection puma ard Fig. 2.71 Assembling Timing Gear Cover the SST (09214 9. Pulley in place ea me s hex head bolt. 82 Es. 09214-60010 Tightening torque: 1100~1500 &g-em (79.5~ 108 feb) 10, the ail pan. The il pan are torque value lo}, aoproxien 1. The gasket has its two sides designated as too block) and bottom (for oil pan) ‘Tne hole configuration tells which side is top oF bottom 2, The dark portions, marked in figure, of the fop side {for cylinder block) are to be coated with the seating compound No, 5 (for cylin Fig. 2-73 Oil Pan Gasket2-24 Engine Top Re-Assembly amie s 2. Put on ihe gasket and se hrod cover cylinder by der head, with the gasket en the cylinder 3. Install the cyl gem roe (79.4~ 86.7 ft-lo) ow 1g the cylinder head on the block, ercise caution 50 a§ not to allaw the straight ins {0 damage the gasketed surface of the 2. Before running in each cylinder head bol; apply engine oil to the underside of its hex head and also to its threaded portion 3. Cylinder head bolts are to be tightened in three ‘or four steps. 1a the lost step of tightening, the bolts are 10 be torqued to the specified Dalue 4. Some combustion chambers may tend to slip out and fall, To avoid this, apply MP gi lightly to the chambers Put in the valve aushrods Install the valva rocker sh: about 2 rotations Tighten the (2) Tur ov shaft exactly one a a), and 4, 5th, 7th and 8th, as counted nents are 10 be secured Fig, 2-76 Assembling Valve Rocker Shaft Tightening torque 150~220kg-cm - Fig. 2.77 Tightening Valve Rocker SupportNote The securing boit for the lower left-hand part of the water outlet housing secures also the alternator adjusting bar. 8. Put on and secure the cylinder head cover Re-Assembly at Left-Hand Side of the Engine the alternator ar ask it pump. 7 the oil filt the filter in pla Olts to the following torque ening ‘orque: 300~450 kg-em (21.7~32.5 frlb) 3. Put on the gasket and install the exhaust manifold, Secure the clamp (for oi! levet 1uge guide} to the manifold nnect the vent place the gasket in th Re-Assembly at Right-Hand Side of the Engine Note For vehicles with a VEype tion pipe. Be sure to joint injection pump, we Section 4, "VExype Injection stall glow slugs and oll 2. Using the SST (09268-46012), install noz zle holders. The nozzle is to be torqued this, valve Tightening torque: 600~800 kg-cm [43,.3~ 57.8 ft-lb) 3. Fit the packing ring, and run in the nut, the nut snug tight, Int the by tightening the screws. Tighten the nut zle leakage pipe, a secure it When instalting replacement pipes for leakage pines No. 1 and No. 2 and fuel return pipe, apply seal packing No. 4 to the pipe side at each joint and fit ipe end positively by using a clip, 5. Insert the injection pump shaft (splined) into the timer hub, indexing the two timing marks (1) to each other, one mark being on the shaft spline and the other on the hu 8. With the timi indexed to the, mark (1] on timing ure the pump in place by 82, tightening its mounting nuts, First, time a Second time Fig. 2-78 Valve Clearances Adjusting Sequence Fig. 2.81 Pump Flange & Engine Aligning Marks2-26 7. Put on t manifold intake ening torque: 150~220 (10.8 ~15.9 friby 8. Insert the oversi n wire into thele on injection magnet, and install ith the mating marks (1) inde: accurately, lock the wire. 9. Install the hose connecting the venturi to the magnet governor. 10. Install the fuel filter el pipe. Re-Assembly at Rear End of the Engine 1. Take down the engine e and set it on the engine holder. 9 pins. Se There 2 6 bolts to be shown in figure. ening torque” 1050 ~ 1250 kg. (75.8 ~ 90.3 ft-b) 3. Mount the flywheel housing in plac install the starter and Inspection after Engine Installation Note: For vehicles with a VE-type inje ion 4, "VE-type Injection Pump”, mounted ar the engine proceed as follows: 1, Fill up the cooling system and engin: pan. Cooling system c ty: 10 liters (2,6 US gal) Oil pan capacity: 7.0 litres (1.85 US gal) The capacity figures, above, refer to cool water and engine oil to be added initially. 2. By refering to the informat 9 3. Check to be sure tt How plug ed hat or glow in secan “glow"” a glow con. of iurming the starter position, {For vehicles troller} 4 rt up the engine. Observe the gauges and me proper indication while the engine is running 5. idle the engine to warm it up. With the engine b: ‘oper operating temp! a adjust it as neces: heck the Fig. 283 Assembling Fiywhee!Valve clearance (hot) Intake : 0.20 mm (0.0078"} Exhaust 0,36 mm (0,0145") 2-27 Check the compression pressure, as shown in figure Compression pressure: 27 kg/cm? (385 psi) as 260 rpmMEMO —50-FUEL SYSTEM (A TYPE INJECTION PUMP) DESCRIPTION . SPECIFICATION 2.0... 0.62. eee se eee ee eee e teens 3-3 FEED PUMP FUEL FILTER . INJECTION PUMP ... 22.0... c cece e eee e ee ee eee 3-8 AUTOMATIC TIMER NOZZLE, NOZZLE HOLDER3-2 DESCRIPTION — — a “a Fig. 3-1 Fuel System The injection pump and nozzles are the major working parts of the fuel system, They are precision-machined parts, finished to very close tolerances and working with extremely small clearances. It is the highly accurate finish and small clearance that account for the ability of the fuel system to handle the fuel oil at such high pressures as are necessary for spraying the fuel into the air compressed to igniting temperature within the engine cylinders. The satisfactory and long-life performance of these parts depends largely on the cleanliness of the fuel oil they handle, Dust particles, particularly abra- sive ones, carried in the fuel oil foul up or wear down the critical portions within them, Water particles mixed in the fuel are harmful, if not equally damaging. Because of the importance of the cleanliness of fuel oil, filtering means are located here and there in the system. The fuel tank has a strainer in its, filler. The fuel pump, shown as (2) in the above diagram, draws fuel from the tank (1) through the pump filter (3) and delivers it to the injection pump (5) through the supply of fuel oil to be used in filling the fuel tank should be clean and perfectly free of any foreign matters. The injection pump is an assembiy of several pumping elements. Each element pressurizes the fuel oil and delivers it to its injection nozzle (6). A part of this fuel the leakage pipe (7) and returns to the inlet side of the fuel (feed) pump (2). lows back from the nozzle intoFuel Feed Pump This pump is composed of two individual pumps, fed pump and griming pump. The former is driven by the injection pump camshaft to feed the injection pump; the iatter is a manually operated pump and is used for the purcose of priming The feed pump is 2 positive displacement pump of reciprocating pision type. It 's adjusted by means of the spring urging the piston to discharge fuel oil at a pressure between 1.8 (25) and 2.2 kg/cm? (308 psi). At this pressure, the fuel goes into the fuel chamber within the injection pump. From the chamber, which is always <2pt filled positively even when the engine is burning the fuel at a maximum rate, the individual pumping elements {plunger pumas} of the injection pump receive the fuel The pressure range mentioned above satisfies two requirements: to ensure the fufl fual supply to the pumping elements and not i9 make thycontrol rack unduly resistant to the cantro! force acting on it, Too high a pressure in the fuel chamiber wil prevent the rack from moving lightly. The priming pump, shown in figure, is operated only for priming, that is, for driving air out fuel line terminating in the said fuel chamber. To. 20] use it, qwist the knob (located on the ume counterclockwise to unlock it, and push it repeatedly, When not in use, the knob is 10 be kept locked. Twi 2, Leaving the knob locked. Twisting it clockwise locks it in place. Leaving the knob unlocked may result in shortage of fuel supply by the feed sump. to tha injection pump, jing it clockwise focks it in Check valve Fitter Fig. 3.2. Fuel Feed Pump Construction Fig. 3-3 Feed Pump Operation Diagram Fuel Pump Operation How the feed pump operates will be explained by referring to figure, wherein one cycle of piston movement is shown in these stages, 1, 2and 3 Camshaft (1) actuates piston (5) through tappet roller (2) and push rod {3}. Piston is urged toward camshaft by spring (7) In stage 1, piston has moved down because of the soring, forcing fuel under i: into the pressure chamber and drawing fuel into the space over it through inlet valve (6). Outiet valve (9) remains closed during this stage. In stage 2, piston has been driven upward. Fuel aoove the piston gets forced out and flows around into the space below. Inlet valve remains closed bout outlet valve is open In addition ta the normal pumping cyclz re. presented by stages 1 and 2, stage 3 occurs when the back pressure on the giston is close to the upper limit of the 1.8 — 2.2 kafem? (25~30.8 osi) range, The back pressure orevents the piston tom coming down all the way so that the stroke becomes redured more or less 10 desrease ‘uel delivery toward the injection pump. At the 2.2 kg/ern? 120.8 psi} or thereabout, the piston sill stay up and beyond the reach of push rod (3) 10 defeat aumping action, resulting in no delivery of fuel3-4 SPECIFICATION Sliding clear Slideng | Piston full sv Suction per between housing and piston ce between how aiston rane (0.00035 ~ 0.00051" (0.00012 ~ 9.00024") Delivery pe formance Priming puma stroke Priming pume suction performance FEED PUMP oft m with f YOU cermin’ gia. ni 25 mm (0.98") Delivery strokes per pumping cycles ay Removal 1, Remove f pipe connection Loosen the 3 nuts assembly in plac uring and remove the pump. Cover, priming pump Pump’ sub-assembly, priming Plug. eh chamber glug Sorina, valve Valve, feed pump check. Pash fod, feed pump Block, tapper sliding Tapper, feed pump 10. Roller, feed pump taooet | 11. Pin, feed puma tappet roller | 12. Ring, feed pump tappet 13, Screw, fuel pipe connection 14. Washer, fuel pipe union pump fuel | 16. Plug, feed puma piston chamber 17. Gasket, piston plug | 18 Spring, feed pump piston | 13, Piston, feed pump 20. Housing, feed pump 21. Serew, fuel pige connection Fig.3-5 Feed Pump RemovalDisassembly 1. Removing pr feed pump tapper, d spring, he push rod is fitted in the housing with a very small sliding clearance, and should not be removed uniass necessary. If the push rad has to be removed, note its position before removal; and be sure to store it to its original position in re-assembly. jemove fuel filter from che hollow of fu pipe inlet tion screw. Inspection Test the priming pump as follows: Close the pump inlet opening by putting the thumb to t, 88 shown :n figure, and pump the knob to see if vacuum di inside. The thumb the um, & priming pump failing of allowing the knob itself (under the be reglaced by a 12 Of the spring) mu: return the filter for cleantiness, Examine it f any of it is in ruptured cleaned every 100 hour or 6 3 0 figure, check parts of wear: (1) piston, (2} push rod, (3) tape roller, (4) roller gin and check valve. Aa excessively worn part must Fig. 3-8 Priming Pumo Inspection Fig, 3-9 Tappet Roller Inspection3-6 Re-Assembly i. Insert piston and piston spring into feed sump housing, Fit ring and install piston Note chamber plug, Install oush rod, tappet spring and tappet, and secure them in place by fitting snap ring. nsert each check valve and valve spring and run in check valve chamber plug and priming ‘tively. Be sure to have each cing fitted properly before installing the plug and puma. he priming pump cover is to be installed after the feed pump is tested. Fuel Feed Pump Performance Test The reassembled fuel fe: ng ta the folloy pumg must be ing procedures before ted A pump not meeting the test criteris on suction performance and delivery performance must be repaired or replaced. The test is to be run in a tester specified for the type of the pump under test Replacement of defective parts, if any, is usually effective in repairing the pump, ion Performance Test Note This testis based on the following test conditions: Suction pipe inside diameter: 8mm (0.315") Suction pipe length: 2 meters (78.74 ft) Suction lift: 1 meter (29,37 ft) Operate the priming pump at a rate of 60 les per minute, with ugh its full stroke, The appearance d within knob pushed in iterion is — mm G ) mw & Fig, 3-10 Assembling Piston & Roller Fig, 3-12 Priming Pump Suction TestInstallation3-8 FUEL FILTER Description The fuel ted on the engine hanger, is case type with clips for fastening its cao to case, Contained in the ca pleated paper filtering element, Undoing the cligs readily alfows the cap t removed, so that only little bother is invo! he filter. Two "0" rings are used the joint between cap and case, servi Removal 1. Disconne: 2, Remove the engine front hanger with t fi tual hoses from the filter. complete Disassembly Undo the clamping ring, and draw out the upper body and fuel filter element 2. Remove the two "0" rings [filter cylinder gaskets) Inspection inspect the fuel filter body and element for distortion and damage. Replace defective par necessary. Note The fuel filtar element should be cleaned with @ bristle brush such as a tooth brush, and should be renewed every two years, Re-Assembly The reassembly procedure is reverse disassembly pro! Nowe. Use new "0" rings Installation Re-install the fuel filter by reversing the procedure. Notes: 1, When purging the fuel hose by operating the priming pump, check to be sure there develops 10 leakage of fuel oil from any part of filter 2. The venting plug ss t0 be tightened after the priming pump knob is locked na Tuo! Plug, air vent Oring Screw, fuel pipe connection Washer, fuel pipe nip! Body fuel filter upper body Gasket, fual hiter cylinder ment, sub-assembly, filter Case, fuel fieer Fig. 3-1. Fuel Filter ComponentsINJECTION PUMP Description Fig. 3-20. Iniect is used as th in| A type A Bosch p on pum for tha 2U engine This pump supplies fuel the injection nozztes in such a way 3s idling, ace eed operation, optimum econom 9 mei fuel requireme: higt high-load as well 3s low-load operation. The components ernor (2) (4). The pump oraper is number of ments a cylinders, Each elamant is composed essential cylinder (barrel The control of th fuel supply to the pneumatic g pressure present in governor is a T ts for starting running of engine da plunger. the intake MN which is v particularly for low The engi By injection thus jorming on Pump Assembly @ timing ge camshaft with a1 shaft runs half as fai ction is initiated eights built in it. Th: Timer by wanical_ fly espond to 7 drive speed to 2 ne for changing th: between driving side and driven d inside jection pump hanges 1@ timing cox nshaft Fig. 3-21 Automatic Timer3-10 Injection Pump Proper Riaference ig made to the injection pump cross section shown ‘r figure and also to the injection. quantity contrai diageam given in figure. In. each of identizs! pumping elements, plunger (1) recigrocates in cylinder (2), admitting fuel oil into the cyiindar through the feed hole (4) and forcing it through delivery valve (5). From this valve, the fue! oll goes to the injection nozzle to get sorayed into the swirl-type combustion cham- ber in the engine cylinder The sliding fit of plunger in cylinder is produced by the most exacting type of lapping, such that the two are handled as a set. Thus, exchange of plungers among the pumping elements is not permitted. The plunger has a helical recess cut out in its cylindrical surface, and also a hole extending through the plunger body to communicate the recess, called the control groove {3), to the space above the plunger top. The cylinder is rigidly held by the injection pump body, and its lower part is surrounded by control 2 (8) capat’2 of a limited rotation around the The bottom end of sleeve (6) extends irom the cylinder and has vertical notches. Driving face (3), which \s a sort of flange formed integrally with plunger (1!, is engaged slidably engaged with the vartical notches. The control pinion (7), rigidly mountad on the control sieeve, is meshed with the bar like contro} rack (9) Thus, plunger [11's capable of two motions: one is upand-dowa motion produced by drive from cam and tazaat down below and the othe the angular mozion initiated by the linear move ment of control rack (9). As the rack 19) is moved pinion (7) rotates sleeve (8), thereby rotating plunger {1} by turning the driving face 18) of the cylinder, the the plunger. Fuel Injection-Quantity Control The reiative positions of control (31. plunger top and feed hole (4) are such that the angular position of plunger (1) relative to cylindar (2) determines the effective pumping stroke of plunger. During usward movement of plunger, the moment the plunger top covers up the fesd hole corresponds, roughly, to the beginning of in and moment the control groove uncovers the fez! hole corresponds similarly t0 tha and oF injection. The schematic diagram of figure explains how the effective pumping stroke of plunger is changed groove jection; tne —30- Effective. Stroke? Fig. 3-23 Fuel Controt System by moving the control rack. Note that the control groove is helical so that the vertical distanc: the plunger to to the groove varias. When control rack is pulled out all the way toward governor side, the plunger is at chat ang position which kegos the feed hai uncovered, so that no pumging action takes glace and, con. sequently, the injection quantity s zera. the contral rack brought to :n2 d9pasite and. the iongest too-to-graove di point of che plunger comas into register wath cme feed hole, so. that the effective pumping stroke 13 maximized to ntity for each result in the maximum iaj stroke of tha piuinger thera ‘on aes3411 Delivery Valve The fuel oil. being forced through the delivery valve into the injection line is at an extremely high pressure. This valve serves two purposes: to act like a check valve and to snappity reduce the line pressure for sharp cutting off of fuel injection at the injection nozzle, thereby preventing the nozzle from dribbling The valve has two active parts in a single body. One is valve (2) and the other is relief piston (1), figure. When the plunger descending, valve {2) is firmly seated under the force of spring, so that the fuel in the injection line will not be sucked into the expanding space above the plunger. This is a check valve action At the end of pumping action of the plunger, the fuel pressure in the space above the plunger begins to drop. If the delivery were to close instantly, the highly pressurized fuel in the injection line would be trapped, causing the injection nozzle to dribble. This is not desirable, and is avoided by means of relief piston (1) as shown in figure. As the valve comes down upon termination of pumping action, the relief piston enters the bore to isolate the injection line from the pumping element. Thereupon, valve (2) and piston (1) go down a little further until valve (2) seats, By this extra movement, a small volume of fuel is drawn Out of the injection line to reduce the pressure in the line, This volume, called retraction volume, is the key to the sharp ending of fuel injection without accompanying any secondary injection (dribbling) Venturi Throttle Valve This valve, called the venturi for short, is a means of producing a differential pressure for the Pneumatic governor mounted on the injection pump body. It is located in the air intake line, between the air cleaner and the intake manifold Figure whoes the venturi cross section and two pressure transmitting pipes. ‘A venturi in general is a constricted passage of air, designed to produce a localized high velocity of air. As such, this venturi has a throttling valve disc, and an auxiliary venturi (additional restriction), which is located in the inlet end of one of the two pies. The pressure differnece between the two pipes varies as the square of air velocity. A small change in air velocity large change in differential pressure. The present MN pneumatic governor utilizes this relationship to control engine results in a Sno Opened Fig. 3:24 Delivery Valve Operation an ‘Opened Operating stroke UL Fig. 3-25 Delivery Valve Operation Operating stroke Fig. 3-26 Venturi Crose Sectional View speed in a highly effective way, preventing the ie from “hunting” and overrunning under all operating conditions3-12 PNEUMATIC GOVERNOR Description Idling spring capsule Governor cam Fig. 3:27 Govenor Crass Sectional Vie Internal combustion engines in service have to maintain a constant speed or to run within a limited speed range wide enough for engine for engine duty. Governors are means of enabling the engines 10 satisfy these requirements and serve the purpose by matching the fuel supply to engine toed, All-speed governors are for constant speed contro! within a given speed range. Speed-limiting gov- ernors are primarily for limiting the lowest and highest speeds. The MN pneuma' employed in the present 2J engine is an all-speed governor having an excellent low-speed stability characteristic, and operates by utilizing the neg: tive pressure present in that part of the air intake line close to the manifold. This governor is mounted on tha rear end of the injection pump body. It has to compartments, A and 8, partitioned by a diaphragm, as shown in figure. Compartment A is communicated to the air horn or upstream side of the valve disc in the © governor Governor stop lever venturi, Compartment B is communicated to the xiliary venturi, which may be considered to be on the downstream side of the valve disc. The diaphragm is connected to the end of the control rack, and is urged by the main spring in the direction for increasing fuel injeftion quantity. With the engine running, a negative pressure due to air velocity is transmitted to compartment B and the full air pressure on the air cleaner side applies to compartment A, thereby introducing a dif- ferential pressure across the diaphragm. It is by the equilibrium between the force due to differential pressure and the force of the main spring that the diaphragm takes its position and thus determines the rate with which the injection pump supplies fuel t0 the engine How the governor operates will be explained for three stages of control, namely, IDLING CON- TROL, HIGH SPEED CONTROL and ENGINE HALTINGGOVERNOR OPERATION Fig. 3:28 Governor Linkage Construction Idling Control in the ventur fully Conse: diaphragm ke: against dling Load on an id fails, less than bet original idlin3-14 Low speed revolution at light load High speed revolution at light load Fig, 3:29. Governor Operation an come only when the e close to idling inkage detween m2 pedal is located nex ial posi joned by pushed in all condition, th diaphragm for 1 speed in High Speed Control ng the a oan. As a result, 1 B becomes lass na to displa: ing fuel injection quantity. In the diaphragm pushes the ri jecessary for actuating the ot he position for fulload maximum dal is re me more ing the diaphragm to pull Enging Halting p bu causes the cont 0 the py ‘on out at th wire connects 12 09 bi the engine comInjection Pump Specifications Direction of camshaft rotation {as viewed from drive side} | Cam sift Pumping element | Injection order Control rack sliding reststance Pre-stroke Anguiar interval between injections Tappet clearance Thicknesses of tappet adjusting shims Camshaft thrust clearance Thicknesses of camshaft shims Plunger spring Delivery valve spring | Pneumatic governor Main spring | Thicknesses of main spring adjusting shims Idling spring Thicknesses of idling capsule shims and washers Clockwise 8 mm (0,315") 7 mm (0.276") inside diameter (with left lead . helix) 1-2-4-3 150 grams (starting resistance) maximum: 50 grams (at 1000 rpm) maximum 1.9 — 2.0 mm (0.0748 ~ 0.0787") at 10 mm (0.39") rack position 89°30" — 90°30" 0.2 mm (0,00787") minimum 0.1 — 1.4 mm (0.0039 — 0.055") in 14 thicknesses 0.03 — 0.05 mm (0.0012 — 0.0019") 0.1; 0.12; 0.14: 0.16; 0.18: 0.5 mm (0.6039; 0.6047; 0.0055; 6,0062: 0.007: 0.019”) 49.4 mm (1.94) (free length) 44.0 mm (1.73) {as-installed length) 15.1 kg (33.3 Ibs} (prioad) 37.0 mm (1.456") (free length) 25.9 mm (1.01”") (as-installed length) 4.42 kg (9.74 Ibs) (preload) Type MN governor operating with negative differential pressure produced by the venturi 102 mm (4,01) (free length) 0.5; 1.0; 2.0; 3.0 mm (6.619; 0.639; 0.078; 0.12") 23.7 mm (0.93") (free length) 0.1; 0.2; 0.5; 1.0 mm. (0.6039; 00078; 0.019; 0.039") Injection pipe specifications Full length of pipe Inside diameter of pipe Outside diameter of tipe | 430 ~440 mm {16.93 ~ 17.32") for all pipes except for No.2, for which the length is, 375 ~ 385 mm (14.76 ~ 15,16") 6 mm (0.236") 2mm (0.078")3-16 22 t 28 ca) S—29 &—s0 | Retaee‘cetwery vate (T= 220°"50 koem) «22. ug. felt plate (t= 550" 780 kpc! |B SO dstecry wae 23. Screw, crsin 3. Gatkel elvery valve 28: Pasion, plunger controt 5. Valve, devery & Element subassembly, injection pump 26. Seat, spring upoee 4. Gouge, iiection pur ll evel 27, Spring pump plunger a Nipile,overiow 3a. Sec Sorng lower |S ban 25. Bia, teopet adlusting shim 10, Pipe overtiow 30. Toopet enembly, njecon pump 1 Nie Bi Cavers conwal eek 12. Gleaner. injection pum 32. Nipole tel pe 13 Screw sirbleeser 35. Screw ful pipe connection 1a Ripple, uv leccer Ses 1S. Hawsitgsub-essembly, inietion pume 35. Shaft slined 18 Seromrvack contr 3. Nou Wterround (T = 600~ 700 ko-em) 17. Gover infection pump 37. Gonna, nection pump 18 Beoring Rn 0" 1S. Pete, Somshoft 3S Bewting 20. Fine, camshaft adjusting 30. Fromm’ injection pump at. Key Fig. 3.30 Injection Pump Components No.1 66 —3-17 Ring, snap Spring, retura Capsule, idling Spring, governar idling Washer, adjusting Rod, push Washer, adjusting Ring, snap Wire, over injection Wire, governor housing seal Governor assembly, injection puma Lever sub-assembly, injection pump Bush Spring, bush Ring, "0" 16, v7 18, 19, 20. 21 22 23 24, 25, 26. 27 28 23 30. a1 Shaft, governor Union, venturi pipe Shim, main spring Spring, governor main Diaphragm sub-assembly Capsule, futl stop Lever, injection pump stop Lever’ with shaft, governor stop Cover, camshatt Housing sub-assembly, governor Seal, Levér, over.injection Pipe sub-assembly, injection Clamp, injection pipe Ring, “0” Pipe sub-assembly, fuel Fig. 3:31 Pneumatic Governor Components No.23-18 Removal 1, Turn crankshaft to bring the pointer (on timing gear cover} into register with the engraved ‘provided on the periphery of crankshaf Notes: 1, No. 1 cylinder is now at 13° Before Top Dead Center (TOC) (1) on compression stroke. 2. Check the position of the injection timing mark line mark 12), 2 es 3. Undo two injection pipe clamps (2) and 4 (4) from the ani 5. tion screw on feed overflow pipe. 6. Disconnect control rad {5} from injection pump lever Disconne: over-injection device, 8. Have the over-injec Note: Removal of this cover is necessary because, if left in place, the cover cannot clear the starter when the: injection pump is drawn out for removal 9. Remove the three nuts securing the inj pump assembly in place, and the down pump assembly by drawing it out Notes 1. Make 2 proper provision for preventing fuel oil from spilling after the fuel hoses are disconnected 2. Cover up the openings s0 that no dust wil the disconnected pipes and others, i 3. Befor taking down the injection pump, check the injection timing mark, 10 whieh referen; can later be made, Fig. 3-33 Injection Pump Removal Fig. 3-34. Disconnecting Over.injection WireDISASSEMBLY SST’s and Instruments Needed nila —- Ta F 4 xc ee rh Fig. 3:96 Special Service Tools a 48013) (2) injection pump (09260-76017) (3) ‘tion pump (092¢ emia (4) er 2 46011) (5) (6) (7) zee oak | and record the test results to be compared with | pump after overhauling it 2. Select @ clean work space for overhauling the Injection pump. Place disassembled parts in 2 pan filled with clean diesel fuel oil, grouping the parts of each pumping element together | 09241-76022 Fig. 3.37 Install Pump injection pu: 3. Remove the fuel (09276—~ Fig. 3:38 Removing Feed Pump3-20 4. Undo the sea! assembly assembly. Remove lever housing sui idlin ng capsule 5. Undo the other seal diaghragm housing, and take out main spring and its shims Remove governor Note: Set aside the removed shims, grouping them {0 avoid mixing them with other shims ther ing. Pull off cotter pin connecting bolt, and phragm, Note: Keep the removed diaphragm off engine oil or diesel fue! ot 7. Disassemble the lever housing sub-assembly in the following manner: Note This disassembly should be effected only when necessary, {1} Detach injection pump lever, saring bush and others from lever housing sub-assembly. (2) Remove the screw securing the place, and take out shaft and cam eres a & Fig. 3.39 Removing Lever Housing Fig, 3-41 Removing Diaphragm 4 ey 2 yO. LLC SA CO0es = 009 l Fig. 3-42. Disassembling Lever Housing© 12, inject Using the S$T (09278-46010), rove position. senvici This step is to ing elements, allpumi another Lay down the injection pump on its side, as shown in figure, plate plug by using Remove timer round aut by using two to0is T 092 0 and SST 09266- 46011) Using the SST (09286— splined shaft. Fig. 3-43 Inserting Tappet Insert _-—_ 09263-76013 Fig. 3-48 Removing Spline Shaft13, Remove the screws securing the injection pump flange, and take off the flange together with “O" 14, Remove camshaft. 15. Check the sliding resistance of control rac! as shown in figure. The indicated method will reveal the pulling force necessary for overcoming the starting resistance Specified valve: Below 160 g Notes: 1. If the movement of contrat rack is sticky or otherwise erratic, examine the tappets and control sleeves for evidence of sticking Stickiness noted in control rack movement is often 9 result of one or more parts in malcondition 2. Confirm the end position of control rack travel by moving the the rack as far as it will go in each direction, and make a provision so that the positions can be referred to in re-assembly 16. Using the SST (09272~76011) push up the tappet, and take off the SST (09274— 46011) 17. Remove each tappet in the following man ner: Hold the tappet in the camshaft mber by means of the SST (09274-76010); and carry it out through the camshaft bearing hole by manipulating SST (09273-76011) Note: One or more shims are located on top of the taper, They are adjusting shims, and may come out together with the tappet being removed. Count them and set them aside as a group, identifying the group for the pumping element, to which they belong. Do ikewise for each element of the four, Fig. 3518 py) << = 7 98275-48010 ake / hy § tacit i Fig. 351 Removing Plunger 19, Take out plunger soring , 20. Remove uoper spring seat and control sl (3), compiate with pinion (4) 21. Loosen «: shown in # trol rack guide igure, and draw out 22. Remove each del plate. Remove delivery valve holder (5 Take out dail ry vaive spring (6).Note Be careful not to overtighten the extractor run into the tapped servicing hole ‘oly. governor housing s. Note The governor housing should be removed only when the joint between this housing and the pump housing has been found t0 be oil-leaky or if the camshaft bearing, oil seal or other parts have to be repal 09271-76011 7 Fig. 3.55 Removing Delivery Valve Seat No.1 09271-76011 = ig. 3.58. Removing Governor HousingInspection Wash all fuel can be assembly or must be replaced b Notes: 1. Do not touch with fingertips the sliding surfaces of plungers, delivery valves and the ike 2. The externat parts of the housings should be: washed clean with washing fluid and a soft-hair brush. Tapped hoies should be cleaned by directing compressed air Tne digphragm should be wiped clean with 3 cloth, Naver immerse it in gasoline, diesel fuel Gil oF any liquid used as the washing fluid, Pumping Elements Examine the sliding surfaces for damage. If replacement is necessary, renew the el a8 a whole: replacing its cylinder alo: example, is not permissible Check the fit of plunger in cylinder by the sliding drop test, which consists of the following steps: Tilt the cylinder a little, pull out the plun the way without taking it of lement the cylin as sh des If theplunger gats hisched and stops on the way toward the end, of it relative to the element must be plunger m changing its ang 2 test Delivery Valves 1 Rais sembly; close the battom openi moving part of the delivery valve your thumio agai g the tio o without sticking un opening or bore at the valve ass must be replaced as a whole th the bottor ng eat your thumb, gush in the moving part at t sorings up by relaase it 10 ot, the valve asse! Fig, 362. Delivery Valve tnspection3-26 fails by its own weight until the val must be replaced as a whole replacement set must be tested as set forth in the above, Camshaft and Bearings Inspect for damage and wear the rubbing surface (1), where the oil seal is located, the working face Fig. 3-63 Camshatt Bearing Inspection ‘of cam (2) and bearings (3), of the camshaft. Spin. each bearing to see if it runs smoothly without any noise. A bearing found in bad condition must be replacement tet carding to the following procedure 09960-20017 1. Using the SST (09950-20017), pull the bearing off camshaft. 2 'e bearing outer race the ‘over, Use the SST (09286-7601 3 ment bearing outer ra cover 09286-76011 Fig. 3-65 Removing Bearing Outer Race ng ring, st e and mnshaft, as shown in figui 09285-76010 ig. 2.68 Installing BearingControl Rack and Pinion 1. Inspect the teeth and sliding surfaces of control rack for wear and damage, Replace the rack if found in dk 2. Pinion is to be examined for any damage and localized wear at necessary, tive conditior Q Fig, 3-67 Rack & Pinion Inspection Tappets Tappets are to be inspected for damage and uneven wear of roller (1), bush (2) and pin (3) l Check the play of the roller in place. Replace parts ° cae f the total clearance for the play exceeds the i, indicated below, or if any defective con dition is noted a oF ae t 3 Fig. 9-68 Tapper Inspection ings \ Excessively rusted, damaged or weakened springs measuring shorter than the specified free length must be replaced Plunger spring (n Free length 49.4 mm (1.94") Asinstalled length: 44,0 mm (1.73") Prelaad 15.1 kg (33.3 Ibs} Delivery valve spring (11) ree length 37.0 mm (1.456") As-installed length: 25.9 mm (1.01") Preload 4,42 kg (9.74 Ibs) Governor IN spring (mt) creek ease reees Free length 102 mm (4.01) As-installed length: 30 mm (1.18") Preload. 0.76 kg (1.67 Ibs) Delivery valve b Governor idling spring (iv) spring ‘ding Ss Free length 23,7 mm (0.933") | | 3s Test length 20 mm (0.78) i | s Test preload 1.9 kg (4.19 ths} E ES \ Plunger ‘spring Govermer main spring Fig. 9-70 Spring Inspection3-28 Re-Assembly 1. After inspection, lay out all parts t0 be used in the others re-use parts. Have them alt cleaned by washing and laid aut in o 2. Gaskets and packings removed are not meant for re-use, Replace them by new ones. 1. Using the SST set (09241-76022), set up n pump body on the pump stand 1. Apply the sealing compound, NIPPONDENSO BOND, to the joint facss of governor housing and pump housing before mating them, 2. A hammer may hava to be used in re-assembling the injection pump, Naver use a steelnammer use a wooden mallet or a soft-metal nammer 3 the Check to be sure the rack moves smoothly throu: its full traval range, 4, Insert the cylinder into pump positioning it as gui the locati and the locating natch put (1) in y vylinder, Note Do not drive the cylinder into pump housing: the cylinder is to be fitted ia with snumb pressu Fig 3-74 Assembling Pump Cylinderassembly 6 delivery valve spring (1) ery valve bh 2), and secure by tightening it tentatively Note A torque wrench is to be used in tightening the holder, The final tightening is to be made while resting the control rack for sliding resistance after the plunger has been installed, wa the pump housing, with its top ht down slightly betow pinions and contral s! 1. The pinion is to be mounted on the sleeve in such @ position that the adjusting hole provided in the sleeve registers with the clamp seraw sida of the pinion 2. Move the rack from one end to the other of its re that the pinion is travel range, and check to bs corresponding rotation of 2a: uniformly centered on the rack travel. Observe the pinion rotation while moving the rack back and forth 3, The mesh of pinion with rack is to be checked fon each sleeve right after itis installed, upe spring (2) soring seat (110. Install plunger (1 seat (2), a5 follow } Fit the lower seat to the plunger, and insert plunge;into cylinder by using e SST {09275~48010) Make sure that the numeral puni marked on the driving face comes a1 p side (pump cover side) and 1ed portion of the lower seat looks upward. lower “The punch.marked numeral of the driving face is on the control group side 11. Insert each tappet into the housing by using the SST ser (09273-76011, 09272~76011] With the driving face of plunger fitted into the notches of control sleeve, push in the tappet and, with the SST (09274-48011) hold the tappet there. Note When engaging the driving face with the sleave, make sure that the punch-marked numeral of driving face comes on the outer side, that is, the marked portion of the face points toward you. 12. After the tighten torque ppets have all been felivery valve hold tening torque: Note The holders are to be tightened one atter another. After tightening each holder, feel the sliding resistance of control rack by moving it back and forth. 09272-76011 ee Mating Say, Fig. 3-80 Assembling Tappet Fig. 3.81 Tightening Delivery Valve Houtder Fig. 3.82 Measuring Control Rack Sliding Resistance14, Note Note Apply engine oil to the camshaft bearings, ! camshaft Camshaft has an assembly mark (1) on the face of its fone end, This end comes on the governor side. the injection pump flange, Using the SST (09287-76010), check the axial play of camshaft, and make a shim adjustment, as follows: 1} Mount the micrometer securely on camshaft, With the camshaft pushed hard toward the pump side, turn the dial inwardly. Then, lightly tap on camshaft with the mallet, directing the drive toward tha micrometer, and turn the dial farther inwardly. Take the reading, which is the camshaft end play. Standard camshait play 0,03~ 0.05 mm (0.0012~ 0.0019") If necessary to adjust the play, in. crease or decrease the camshaft shim plate thickness by replacement. For this purpose, replacement shims are available in the following selective 0.10 {0.0039}; 0.12 (0,0049"); 0,14 (0,0086"); 0.16 {0,0063"); 0.18 (0.007"); 0.50 mm (0,019 The method of replacing the shim piate is covered in the section dealing with camshaft bearing replacement After adjusting the piay, put on and secure the injection pump flange. Be Sure to use the sealing compund on the face mating with the flange and fit the ing snugly to putting on the flange, 3-31 Fig, 3-84 Measuring Camshaft Thrust Play O-00 == 3:85 Camshaft Shims Fig. 3.86 Installing Puma Flange 313-32 16 Using the 550 ~ 750 kg-cm (39.7 ~ 54.2 felbs Note Use new felt plates, Apply NIPPONDENSO No. 4 grease to the screw threads of each plug 17. Fit the key to camshaft. Secure the soli shaft to camshaft by using the SST set (09278-48010, 09266-46011) Tightening tor 600 ~ 700 kg-om 3~50.5 18, Rotate the camshaft in piace oy means of the afore-mentioned holding tool, Take out the SST (09274-46011) 19, Run the pumping test on the injection sumo thus far assembled. The governor is 10 be installed while this test is in progress. 20. Install the diaphragm, and s re its flange to the governor housing 21. Install the main springspring shim and diaphragm housing 22, Secure the governor diaphragm housing and lever housing in place. Apply NIPPONDENSO No. 24 grease to the shaft, am and lever housing interior before securing the igohragm housing and lever housing, I governor plate and del holder lock plat 24. Mount the tual feed puma assembly on inje mounting face. 25. Fill the pump housing with the diecel oil and apply the diaphragm oil to the diaghra ion pump, with “O" ring fitted t on Pump housing to be filled with: 100 cc of diesel oil Diaphragm to be given: 2 to 4 drops of diaphragm oi 26. Take down the injection pump, thus far built, from the pump stand [F500 700: ig. 390 Assembling PumaInjection pump test Pre-test inspection and preparation 1. Check the open pressure of the testing injection no. Reference opening pressure: 100 kg: {1400 psi} Notes: 1. For the testing injection nozzle, use NIPPONDENSO-make nozzle, PartNo. 0934000080, 2. Check and, as necessary, re-adjust the setting of the testing nozzle every 20 hours of operation 2. injection pipes to be used in the test shail ification m (0.236") 2mm (0.078") 600 mm (23,6") us of pipe bend: 25 mm (0.98"} minimum 1. For the testing injection i NIPPONDENSO-make pipe, Part No. 9-52137. 001-0, 2. Bear in mind that use of injection pines not ‘meeting the specifications may result in a wrong setting of the injection pump under test jon quantity 3 fuel oil to the injection pump under a pressure of 0.5 kg/cm? (7.1 p 4. The fuel feed pump may have to be r from the injection pump. depending on type of the testing equioment used 5. Injection quantity measurement on ¢ pumping element of the injection pump must be taken by receiving the inje (discharged) fue! oil with a measuring cy! inder meeting the spec Nowe: ‘The receiving duration is prescribed to be 30 seconds, Upan clocking 30 seconds,raise the eylinder promptly and take a reading test shall be months, % at 2C at intervals 0} 00 rpm accuracy Fig, 3.9 Puma Tester inspection3-34 manom for the zero Cheek point and water column height, and make sary. This tube is for corrections ssures and must be properly rake available true readings, Note: Writing down the adjustment positions on chart Paper is not advisable because the paper stretches and contracts too widely to provide for reliable 8. (1) into splined ereby coupling the injection pump to the driving member of the test equip: ment, 9. Remove contro! rack cover, install des joint bolts, and mount fuel hose (2), rack scale (3) and injection pipes (4) Note ‘The rack scale is to be such that it indicates the zero point when to control rack is pushed in as far as it will gotoward the governor side, and that the Position can be easily and accurataly read on it. 10. Check to be sure praperly filled with oil, Add oi 11. Purge air out of the injection pump mounted and set on the tester, Testing procedures Control rack sliding resistance ng scale to ms sure the sliding the rack, as shown in figure maximum at 0 pump 150 gr rpm, 50 grams maximum at 5000 p: Nowe Hf the rack pe and associated parts sgreater resistance, repair the rack Fig, 3-96 Installing Rack ScaleInjection Timing 1. Prestroke messu (1) Set (2) Meas. plu position t (at which t pipe prest means of @ dial gauge and the SST (09283-46010) Standard prestroke 19~20mm (0,075 ~ 0.078 s of the shim ger spring lower and the top 0 Note: Replacement shims for this adjustment are available in 14 selective thicknesses, starting with 0.1 mm (0,0039") and ending with 1,4 mm (0.055"), with intermediate thicknesses differing by 0.1. mm (0.0039) consecutively 2, Measurement of injection intervals (1) The end of prestroke (beginning of ction) of No. 1 cylinder is to be the fotlowing specifications ex din terms 0} the beginning of injection of No. 1 cylinder taken as 0 degree Beginning of injection 39°30' ~ 90°30" (No 179°30' ~ 180°30" ( 269°30' ~ 270°30' (No. ethod of adiu: Note Increasing the shim thickness by 0,1 mm (0.0039") advances the beginning of injection by about 30 of crank angie Tappet cl 1) Use the S (09288. the movement of the driving face of the plunger. The face si id not aanas contact wit Fig. 3-101 Adjusting Injection Intervals a , os28s £6013) : : oszedyasp 10. Fig. 3-102 Measuring Tappet Clearanceof the cylinder and there should occur any rise in the resistance of the lever being operated by hand, tandard tappet clearance 0.2 mm (0.0078") minimum (2) If the prescribed clearance is not available, the foregoing adjustmen starting with tha’ be repeated. Nowe: ‘As long as the prestroke and injection intervals are correctly set, the clearance is Bound t0 be at least 0.2 mm, and needs to be adjusted Injection Quantity Adjustment The control slee are to be reposition gularly to increase or decrease injection quantity To do so, the clamp 5: pinion of each sleeve must be loosened. The test running for purpose is to be effected under the conditions, and the adjustment is to be made to meet the requirements, indicated r an- won th v below: Rack [Pump Iaximus position | speed variance! mm tin) | epen " ce 11.0 (0.44) 04 8.0 (0.315)), 4 8.5 (0.26) o 16.0 (0.63) | 12 Note Make sure that fus! oil is available to the injection pump at 0.5 kg/em2 (7.1 psi) Tests on Plungers and Delivery Valves 1. Plunger test (1) Install the test pressure gat ivery valve holc be under test. on of the cylinder to Note: The pressure gauge should indicate 300 zo 400 kgfem2 (4250 t0 5700 psi) as its. maximum pressure, and be connected to the valve holder through 3 80 mm (1,96") long pipe of the same. size as the injectionpipe used in the test (2) Position control rack at the 6. no-load (on engine} position, and fix rack in that position by means of the rack scale. (3) Raise the pump spec he highest pressure indicat the gauge. This pressure shou! 200 rpm, and be at least 150 kg/em2 (2150 psi) Note: This test resupposes the delivery valve to be in normal condition, free feom any defect Fig. 3-104 Measuring Injection Volume Fig. 3-108 Delivery Valve Test2, Delivery val (1) After'noting a pressure of at least 150 kg/c in the plunger test, above, stop running the pump and rack to 0-mm position, (2) Clock the time required for the pres sure within the valve holder to drop to 10 kg/em2 (140 psi) 10 kg/cm? [140 psi drop time: 5 seconds or longer the above time requirement cannot be mat, both plunger and delivery disqualified. In such the pumping element must be re (3) ase, Pneumatic Governor Adjustments 1, With the pneumatic governor installed pro- perly on tha injection pump body, test the governor for air-tightness under the fot lowing test conditions Pump | Drop soeed | in negative pressure | B0Orem | Fram S00mmio | Atleast L480 mm Aa Notes 1, When installing the governor, be sure xo apply NIPPONDENSO No. 24 grease to the diaphragm housing and idling capsule in order to ensure the air-tightaess of the governor. 2. If leakage of air is noted, retighten the securing screws or examine the diaphragm for the cause of leakage. 2. Carry out the adjustment outlined below for establishing trol Negative Rack speed pressure position (1) Adjust the fi capsule for the 10.3--m (0.40 rack position. (2) With the negative pressure of 350 mm Aq 00 rpm, the control rack should came to and stay 10.3--m (0.40) position: if not. idjust by means Notes! “ 1. So that idling spring will not interfere with main spring.bring the cam down to a position forming an angle of at least 30° with the horizontal, as shown in figuee, and have fed in that position by tying with the lever sec Fig. 3-110 Cam Lever Position2. The negative pressure is to be brought to the desired level after changing it widely. Read the pressure on the scale when it nas stabilize, The specified. free length of main spring and the thicknesses of replace. ment shims are as follows Main spring free length: 102mm{4.01"") Shim thicknesses: 0.510.0 1.0 (0,039); 2.0(0.078"); 3.0mm(0.12") 3. Adjust the to satisfy the following rack position requirements: main. soring Negative | mae | Rack position pressure nm rom_| mm Aq 350 | 10.3 (0,40") {initial setting) 380 | 10.1 ~10,310,39~ 0.40") 600 [ 400 8.3~97 (0,32~ 0.38") 420 62~8.0 (0.24 450 | 6.2(0.24") maximum The adjustment is to be effected by varying the thickness of main spring shim, Notes: 1. Hold the cam lever down is a position forming fan angle of at least 35° with the horizontal, as shown in figure. 2. After making the adjustment, initial setting, 4, Adjust the idling spring to satisfy the following rack position requirements recheck the Pump] Negative a speed pressure pos rpm | mm Aq a 600 B6~9.2 (0.34~ 0.36") 600 s00 | 78~84 (0.31~ 0.33) 1000 72~75 (028~0299) {initial setting) (1) The adjustment is to be made by replacing the shim and washer con- tained in the idling soring capsule Replacement shims and washers are in four thickness of 0.1 mm (0,0039"}, 0.2 mm (0,0078"), 0.5 mm (0,019") m {0,039") (2) k locates itself off the Positions indicated above when the negative readjust oressure is 6 main spring set of initials rack pos \ O WANN © / Fig. 3-111 Main Spring & Shim Fig. 3-112 Idling Spring Caps: fomponents Fig. 3-113 Com Lever Idling Position ee a /Notes: 1 2 from the re: 1 values of negative ective ranges for dif pressure Free the cam lever, and bring it to the position foridling (35° above the horizontal) If athicker shim (1) had to be used to adjust zhe amount of protrusion of the push rod, use 2 washer (2] which is thinnar by anequal amount so that the push rod clearance willremain unaffected. Conversely, use of a thinner shim must be compensated by use of @ thi washer. Push Rod Clearance: 0,3 mm {0,012") 5, Adjust the toal injection quantity Pump Negative | Total injection speed Pressure quantity (4 cyl.) (rom) (mm Aq) | (ec) 1 S2= a6 Tor tH | | S60 stones 8. Seal the diaphragm housing (1), lever hous ing (2} and full stop capsule (3) rl With No. 1 cylinder in. the position for beginning of injection tas explained in page 78}, check sure that the splined shaft mark (3) is in register with the beginning-of injection position, which is off the punch mark on the flange by 78°+30". 1010) to the keyway splined shaft will not turn,3-40 Installation 1. By barring engine piston in No.1 cylinder to 10° (3) Dead Center. Put t crank pulley securing nuts. Note Have the valve rocker cover removed, and verify this crank position visually 2, Install the splined shaft in automatic time hub, with the match marks (1), (2) index 3. Put on the injection pump mounting nuts tighten the ou ugly, making them finger ove the SST (09284-48010). nanaeral Note Put your hand to the top of the injection pump, and pull the top lightly away fram the engine to take up the backlash in timing gears, Under this condition, remove the lock plate Install fuel hoses for the injection pump, and also the pressure transmitting pipes for the ventur By operating the priming pump, drive air out of the fuel hoses, filter and in, 6. Connect the injection-timing checking pipe ta No.1 delivery valve holder, and turn engine crankshaft b crank sh ca in tha check rving the g pipe (1), Tilt np just a little toward the t the fuel oil surface will rence 10° BTDC 2 when the rel ne injection pump has been mounted the use of the SST (09248-46011), it should not be necessary to make the positional adjustment of the pump, as in step 7 above, for che PUMP Is supposed to be set for thecorr of this setting by observing the rise of fuel oil surface and be ing to the crank angle The adjustment made according to step 7 is subject to error due to human factor. It is ming, Visually make su necessary, therefore to visually note the coincidence betweencrank angle reading and se of fuel ol in the pipe, not just once but 3 for 4 times of even more, injection pump mounting nuts good and hard to secure manen Fuel injection timingWhen the moving core is pushedi n fully, face of the core should come into register with the match mark provided on tha arm. 2 end Fig, 34 Over-injection Magnar Aligning Mark length of the governor ting rod to the dard vaive. Note ‘There is no need of sealing the adjusting screw afte and read and steady3-42 AUTOMATIC TIMER Description Fig. 3127 Automatic Timer The automatic timer advances the injection timing when the engine speed rises. The timing advance and the speed rise are in such 2 relationship as to ensure the optimum injection timing at all levels af, speed The main working parts of the timer are two

>> | Confirmation position} Less than 05 a ae ood (Less than 0.031) | ~ lhceummaucn 7 =131 =4-30 ADJUSTMENT STANDARDS (2J-T) 1,” Adjustment conditions Nozzte NIPPONDENSO Part No. 093400-0540 Nozzle opening pressure 145 — 155 kg/em? (2062 — 2204 psi) Testing oil JIS No. 2 light oil Oil feeding pressure 0.2 kg/cm? (2.8 psi) High-pressure pipe (inside dia. x outside dia. x length) 2.0 x 6.0 x 840 mm (0,079 x 0.236 x 33.07") Testing oil temperature 40 — 45°C (104° - 113°F) Solenoid voltage at adjustment 14v 2. Temporary adjustment (lever at FULL position) Pump speed Injection volume rpm | 0/200 st {cu-in/200st) | cee Full load faa 9.0 ~ 10.0 (PB=400mmHg] | Adjustment by full load standard point (0.55 -0.61) set screw High speed lever 5.0-9.0 (P&=400mmHg] | Adjustment by maximum setting point zoo) (0.31 -0.55) | speed adjusting screw 1200 6.2 ~6.8 (88.2 - 96.6) Note: Pa: Boost pressure (Use a manometer and apply a correct pressure.) 3. Pump internal pressure (lever at FULL position) 7 Pump speed Pump internal pressure pone rom kg/cm? (psi) jemarks 400 4.2 ~ 48 (59.8 - 68.2) Adjustment by regulating valve 4. Overflow rate inspection (lever at FULL position) Pump speed_ Overflow rate . rom cofmin (cu-infmin) Cee 5 Use the overflow screw installed 1200 | 350 — 770 (21.4 - 46.9) Roe ipa 5. Timer adjustment (lever at FULL position) Pump speed ‘om 600 750 900 1100 Piston stroke 01-08 06-14 12-20 12-20 mm (in) {0.0039 ~ 0.031} {0.024 — 0.055) (0.047 — 0.078) (0.047 — 0.078) Note: The hysteresis for each speed shall be within 0.3 mm (0.012"). 132 —4-31 6. Boos: comgensator adjustment (lever at FULL position} Injection volume Hysteresis oesteas | eaosu beets ‘cc/200 st 0/200 st Remarks coe as) (cusin/200 sth {cu-in/200 st} 7a—T7 Check unnecessary | Minimum injection 2 (0.44 - 0.48) volume at full lose 78-84 Less than 0.3 | Boost compensator eon ioe (0.48-0.51) | {Less than 0,018) _| characteristic inclination of boost 200 87-98 Check unnecessary | compensator character- (0.53 — 0.56) a 92-96 250 (os 059) | Check unnecessary Note: After each setting change, move the adjusting lever one going and return between the IDLE and FULL position before measurement 7. Injection volume adjustment Injection volume Pump speed | Boost pressure 7 Dispersion a Lever angle ce/200 st Remarks ee ‘om mmHg | (eusin/200 st)_| & (curio) 93-95 0.4 | Full load standard in. oo oo (0.57 - 0.58) (0.024) | jection volume setting 56-84 High speed lever ed 400 | 34-051 | 7 | setting i 7 1300 400 Raion = | Confirmation nee Less than 06 (FULL 1400 400 | = | Confirmation Leche) {Less than 0.037) | | —_ 1120-150 | 1.0 | Votume increase at = (073-091) | (0.061) | start 76-98 05 | 5 325 2 foetal | (o03)_| Vole increase end 68-74 05 400 9 (ods 0.45) | (0.031) | Confirmation 1100 400 1028 280) | 10¥Sr) | Confirmation 8. Low speed ever setting 1 Pump speed Injection volume Dispersion | 7 Lever angle rpm c¢/500 st (cusin/800 st) | ec (cuin) | Bones 325 3.05.0 (0.18-0,30) | 1.0 (0.061) | Low speed lever —18° £5" More than 10.0 | (OLE 250 (More than 0.61) = Confirmation position) Less than 0.5, i $00 (les inen 0.031) = | Contirmavon = 133 —4-32 INJECTION PUMP ASSEMBLY REMOVAL Note: © The injection pump can be removed in either of the two following ways. Select the m: to the repair contacts. This manual describes the procedure for 1 1 Remove the injection pump from the engine which has been removed from the vehicle 2 Remove the injection pump from the engine mounted on the vehicle. © When removing the injection pump from the engine mounted on the vehicle, first remove the following parts before starting removal according to the procedure described in this manual 1, Rear toe-board 1od according 2, Engine hood 3. Battery 4. Disconnect the accelerator wire 5. Disconnect the fuel cut solenoid wiring 6. Weight 7. Drain water from the radiator 8. Radiator and fan shroud 1. Remove injection pipes. (4 pipes) Fig. 4-41 Removing the Injection Pipes 2 Fig. 4-42. Removing the Fusl Pipeinjection pump side} w to boost pensator). {2-T) Remove the fan Remove the fan belt Remove the alternator Fig. 4-46 Removing the Grankshatt Pulley9. Remove the timing gear cover. 10. Remove the pump drive (1) Punch matching marks on the pump the crankshaft to align the matching mark for timing gear installation) drive gear and idle gear (or rot (2) Nut (3) Pump drive gear SST 09213-31021 11, Remove the injection pump, (1) Pump bracket bolt and pump set nut (2) Injection pump Caution © Do not hold the adjusting lever for pump removal or carrying, © When placing the pump on the work bench, place it gently. Removing the Injection Pump {2/-T)4-35 DISASSEMBLY Caution > Wash outside of the injection pump, Clean the work bench and workshop for operation. 2 Always measure and record the pump injection volume characteristic before disassembly. If there is an adjustment error or part with defective function, comparison of the characteristics before and after disassembly enables detection of the defect cause. © During disassembly, remove each part while checking the part mounting status, deformation, damage, roughening and scratching © The disassembled parts shall be arranged orderly to clarify those to be replaced and others to e reused move the overtlow screw and drain fuel Use the SST and install the pump to the pum SST 09; ounting bench. 45-4010 Fig. 4-52. Installing the Injection Pump 3. Remove the governar cover nor cover and di trol. spring spring seat Damper soring (4) Governer sori 5) Control spring (6 Fig, 4.54 Removing the Governor Cover (24)(3) Raise the gover the control so 10r cover and disconr from the gov (6) Control sprine (7) Governor cover with boost compensator 4, Remove the fuel inlet union, (1) Loo: use a hex governor shaft SST 09260-54012 Caution: Be careful that the lock nut and governor shaft use left-handed screw, (2) nor shaft, re an assembly Note: Remove parts 1, 2, 3 and 4 as an assembly Fig, 4.58 Removing the Flyo (3) O-ring Remove a (2) (3) (4) 6) 6 plug. wvery valve. Delivery vatve holde! SST 09260-54012 Valve spring seat Valve spring Delivery Valve gasket eal Fig. 4-60 Removing the Solenoid Fig. 4.61 Removing the Head Plug Fig. 4:62 Removing the Delivery Valve Holder = 139 =4-38 Caution © Removed valves and valve seats shall ways be paired, and never use them for different cylinders, Distributor heads are punched with the symbols (A, B, C and D) showing the mating cylinders. Delivery valves and delivery valve holders shall be arranged for reinstallation to the same cylinders. ° 9. Remove the distributor hi (1) Distributor head (2) Lever support 10. Remove the plunger, (1). Plunger spring guid (2). Plunger spring shim (3) Plunger spring upper seat (4) Plunger spring (5) Spill ring Plunger soring lower seat Plunger upper pl: Plunger tower plate (9) Plunger Caution Carefully operate because the adjusting shim under the plunger, (Remained on the cam plate) “ay e—12) Fig. 4.63 Removing the Delivery Valve Fig. 4.64 Removing the Distributor Head Fig, 4.66 Disassembling the Plunger Parts = 140 ~NW Fig, 4.67 Removing the Lever Support Bolt 12. Remove the cam piate (1) Cam Plate 2 ) Governor lever Fig. 4.68 Femoving the Governor Lever Plunger adjusting shim ) Coupling spring ) Couplini(1) Timer cover (2) Timer (3) Adjusti pcs.) (4) O-ring 14. Remove the roller ring and timer piston. (1) Timer clip (2) Stopper pin 11 to the cai roller ring Caution Set the paw! of the drive shaft 90” off from the timer slide pin. Caution © Use long-nozed pliers and remove the roller ring carefully without tilting it. In the roller ring, the height of four rollers, are_made identical. Therefore, do not change the assembling position of four rollers nor change the combi ‘oiler, bushing and roller pin tion of the Fig. 4-71 Removing the Timer SpringCarefull prevent the sub-piston from being ropped drive shat the drive shaft (with gear) up: Caution Carefully prevent loss of the feed pump driving key. elated parts. screws Use wire and insert it in the cover set ‘ew hole for removal. Carefully prevent the rotor and the blade from coming out with the cover and liner, © Avoid slanting and prying{4) Rotor and bi Caution: © The relative positions of four blades with the rotor shall not be changed © When replacement is necessary, replace the rotor, blades and liner as an assembly. 17. Remove the regulating valve. (1) Regulating vaive SST 09260-54012 (2) Ori 18. Remove the oil seal. SST 09612-65014 Note: Install the SST as illustrated, and drive out the oil seal by using a driving bar, etc, 19. Remove the adjusting lever fernor cover (1) Punch matching marks on the lever shaft parts from the and lever Fig. 481 Removing the Oil Seal Fig. 4.82 Matching Marks Matching marks(5) Return pring nsator parts, Fig, 4.88 Removing the Spring and Shim (2U-T)nor link sup} Lever support pin (81 Control lever sub: (9) 9) ay (12)INSPECTION 1. Plunger ch or discolora’ ceived, re part is Fig. 4:90. Inspecting the Plunger lunger is released gensly 3 mm (0.12") by nspection drop by 3 weight, r2 place spill ring ani Fig, 4.91 Inspecting Plunger Sliding Movement SS 0 mm ae O Fig. 4:92 Inspecting the Oelivery Valve and Holder Fig. 4.93 Inspecting the Roller Ring4-46 (2) Inspet dial gat heigh| Limit dispersion of raller height 0.02 m ff the limit is roller positions, table if dis persian becomes less than the limit Fig. 4.94 Inspecting the Roller Height Dispersion 4, Drive shi (1) There shall be no looseness key and key groove yieen the ber (2) Damage (3) Wear at oil seai contact surface Depth wi 0.08 mm (0.0031" Fig. 4.95 Inspecting the Drive Shaft Fig. 4.96 Insp (2) Wear of cam plate at contact surfa with plunge (Measur with a ve c Wear limit L = 4.2 mm (0.1653") nension L 4.97. Inspecting the Cam Plate Wear8 (1) Inspect the sliding co Replat the feed pump assy exces. sively worn or damaged Governor lever and spilt ring (1) Insert the ball pin of the governor lever into the hole of the spill ring, and in spect if they slide smoothly without loose fit Plunger spring (1) Replace the plunger spring with surface defect because it may be broken Caution Replace both the right and left springs at the same time. (2) Rectangularity of sorir Limit rectan Inspecting Wear of Fly Weight Fig. 498 Fig. 499 Inspecting the Feed Pump Fig, 4.100 and Spill 1" 5 Inspecting Stiding between Governor Lever Fig. 4101 Inspectin ea ng4-48 10, Pump housing a surface o (2) 0: (3) Wear drive shaft as Lightly shake the drive he wear If the wear limit is excee the pump housing. (Repla the bushing only is no Bushing wear limit 11. Boost compensator (2J-T) (1) Damage and deterioration of diaphragrr (2) Wear of push rod Wear and damage of lever connecting pin (4) Damage at hausing cov (5) W hing of guide Shake lightly (Force less than 2 kg) Worn part Fig. 4-102 Measuring the Bushing Fig. 4-104 Ins Wear fear Amount of Housing ting the Housing CoverASSEMBLY Caution 2 The assembly procedure is roughly the reverse of the disassembly procedure, but the careful because ere is a little difference in the sequence. 2 Do not let dirt or foreign matters enter ¢ light oil before assembly The work bench and work shop shal! be kept clean and pay careful attention to the operation. 12 pump. Each part shali be thoroughly washed with clean Coat light oil on the sliding contact surfaces, O-rings and oil seals before assembly. © Always replace O-rings, nipple washers, gaskets and joint Assemble boost comps Note: The assembly procedure is the reverse of the disassembly procedure, Since adjustment be fore assembly is necessary for some parts, adjustment method and points requiring special care are explained here (1) Agi Adjust dime of the gover of the shim by changing 1 of dimension L. jon L from the psu top surface he shim thick: over ress. Ad ndard Ly = 198.4" + 0.0089 ‘Shim part No Thickaess mm Gn! 22181.21910.71 22182.21910-71 221832191071 221842191077 22187 218107 22188219107 Temporarily a 19.2 mm (0,756") (2) Adjustment of dimension X Adjust dimension X from the end sur face of the governor cover screw plug alling part to the control lever sa Adjustment standard X 8.8 0,1 mm (0.346" + 0,039") st dimension Lz & lever} as fall Jbber with new ones. Governor cover Fig. 4105. Dimension L (2-7) Fig, 4107 Dimension X 125-7) ~ 151 -ush rod with the spring 2 n it is fully pushed in, measure sion X with a vernier caliper. 3 adjustment standard is not , turn the push rod to make memt. (Since the tapered oa: rod is eccentric, turning fod changes the m lve. Caution © Measure at the center of the plug hole. © Carry out measurement with the shim Fig. 4-108 Measuring Ditnension X (24-71 installed, © After adjustment, mark the adjusted posi tion on the governor cover for reassembly of the push rod. Add 3 - 4 ce (0.18 — 0.24 cu-in} of diesel engine oil {SAE3O or SAE4O) at the position shown in the illustration at right before assembling the diachragm and push rod, (4) Pay special attention to tear of die phragm and leaky seal at lever connect- ing pin sliding contact part. (5) Each part shall be tightened to the torque shown inthe table belove Parte Tantening in Tightening pace forsee ig. 2-9 komt) Tae ZOE | Lui Shared @ | inlet union eel | Lock mut Pate washer ve | Hessen nit ferguae | 25~3 | ar connecting sin | bon Fe | bose nut or gue busing | n side Fig. 4.181 ‘Assembling the Governor Cover (21-7)mble ti s (1) Assembie the O-ring and washer to the adjusting leve 2 lever shaft from inside th soring (4) Adjusting lever Caution: © Align matching marks on the adjusting lever and lever shaft for assembly © One serration of the adjusting lever cor- responds to 7.5° in lever ang check © When replacing the adjusting lev the punched number on the lever is identical Fig. 4-112. Assembling the Lever Shaft Serration Fig. 4-113 Adjusting Lever Fig. ¢ dae 15 Assembling the Adjusting Leverale the oil seal. Note Use a 22 mm box and drive in the oil seal to the end of the pump body Assembling the « (1) Assemble th a Caution Install the liner in the direction shawn in Fig. 2-118, Reversed installation (left and right or upside down) shall carefully be avoided because it will prevent discharge. (Place the staged part of the side surface at the top in the figure.) Caution: © Assemble the rotor and blades as shown n figure. Install each blade with its grooved side facing inward {toward the rotor center). The rotor and blades sh slide smoothly, © When replacing the feed pump, always re place it as an assembly (rotor, blades and liner) Driving in the Oit Seat SB es Fig. 4-117 Assembling the Regulating Valve Instaiting the Liner SS Le TReversed(3) Feed pump Caution Check the fuel discharge hole position of the feed pump cover, Reversed installa. tion is not allowed After cover installation, make sure that the rotor slides smoothly up and down and to the left and right. Fig. 4-120 Installing the F: Assemble the drive shaft 1) Instat vernor drive gear to the drive shaft and rubber joint to i the drive shaft and d Caution > When installing the governor drive gear, direct its indented side toward the paw! side of the drive shaft. Use a new rubber joint. Fig. 4-121 Installing the Governor Drive Gear the rotor key groove upward, the rotor drive key and thrust to the shaft and assemble the shaft and rotor with correct mating of the key and the rotor key Check smooth rotation after cove assembly ig. 4.122 Assembling the Drive Shaft s of the rol so that their curved surfaces face outward The slide pin shall be inserted fully the center as shown in the figure at light, Fig. 4.123 Installing the Timar Slide Pinshown in the figue Caution: Carefully prevent dropping of the roller Install the roller ring so that its notehe: part faces the upper side of the oump housing ing gre grease] 0 Caution © Install the piston so that its low pressure end (timer spring side) comes to the right as viewed from the pump drive side. Also check that the fuel inlet hole of the pump housing is on the low pressure side. The hole on the sub-piston shall face the timer slide pin, Insert the timer sl Th Caution: Make sure that the timer piston slides smoothly lasts : the following o 1 3 er spring Caution: At least 0.5 mm (0.020") thick wa: be placed at each end of the spring, Fig 412510. Install the c (1) Coupting (2) Instalt che cam place with its pin diret toware the key groove af the drive sha: pling and cam plate Caution © Install the coupling so that its larger center hole faces upwards. © Carefully coincide the cam plate pin with the drive shaft key groove to prevent incorrect injection sequence. Do not install the coupling spring in this step. ° Fig. 4-128 Installing the Coupling snd Cam Plate 11. Plunger soring shim adjustment (Measure ment of dir: (1) Dimensian KF is the distance between the end surface of the distributor cy linder end the end surface af the plunger head. The plunger spring set length shail be adjusted by changing the thickness ot the plunger spring shim (selective use) (2) Assemele the following parts to cylinder head Plunger spring guide cylinder Plunger 1 2 Upver soring Fig. 4129 Dimension KF 3 2° spring — 4 1 spring sea 5 er upper piste 8 er lower plate u at Plunger loMe" D8 anger upper Caution “plate --Lower spring seat ‘© The plunger spring shim shall not be in: stalled in this step. © The spill ring shall be removed Plunger soring guise Fig 4.130. Assembling the Plunger TemporarilyShim thickness mm {in 228) — Caution 2 Use the plunger spring shims of the same thickness on both sides. (Use two identical shims for one pump.} If the shim exactly as thick as the cal: culated value is not available, select the fone whose thickness is nearest to the calculated value on the greater side 2 When replacing the plunger spring, replace the left and right springs as @ pair. dimension <) a olunger shim of an arbitrary thickness and install th Caution: Do not coat grease on he plunger shim, Fig. 4131 Measuring Dimension KF Distributor ey Seep evlinder Fig. 4-132 Dimension K Installing the Plunger Shim Temporarilyhit the distributor head and Caution © Turn the drive shaft and check if the plunger rotates © Hf the plunger does not rotate, carry out reassembly because the cam plate pin is not in the plunger groave. 0.0039") Caution Make sure that the plunger is not raised at the time of measurement, m selection er shim thick comparing the measured value w standard. Shim thickness {mm} =n Flt, =3.3) Shim fio} ty 0.130) hickness of the shim F measures read, plunger Fig. 4-134 Installing the Head Temporarily ig. 4.195. Measuring Dimension KInstall the cam plate. Caution Install the cam plate so that its drive pin is aligned with the drive shaft key groove. Carefully prevent misalignment because it will cause incorrect injection sequence, Caution: Install the spill ring so that the end surface with a hole always faces the cam plate (2) Insta spring low 1 Plunger spr Spring upper seat Plunger spring shim (sele 4 Plurger spring guide Fig. 4-126. Installing the Coupling Spring Fig. 4-139 Assemds the Plunger Parts (2),(3) Plunge’ ed one) Caution Do not coat grease on the plunger shim. (4) Install the assembled plunger shown in the figure right. Caution Install the plunger so that the m plate drive pin enter the groove at the plunger leg. Install the governor lever ) Governor lever Caution Install the governor lever so that the ball pin surely fits into the spill ring, (2) Support bolt T 09260-54012 T=10-1.3kgm 7.3 — 9.3 feb) Note Adhere the spring by grease (Denso grease =50 or timer grease) to the hole in the distributor head (2) Install 2 distributor head. Caution © Direct the lever support sprit ‘the governor lever in assembling, © Push the distributor head with a hand up. to the O-ring installing part toward Mie A Fig. 4.140 Fig. 4-141 Fig. 4.142 Installing the Plunger Installing the Governor Lever Installing the Support Spring stalling the D) stributor Head4-60 3). Distributor head set bolts T=11-13kgm 0-9 Caution © Alternately tighten four bolts evently, © After tightening, operate the governor lever to check if the spill ring follows smoothly 18, Instatl 1) Install the O-ring to the 2). Head plug SST 09260-54012 T=6.0-80k e head plug Caution: Always use a new head plug. Caution © Always © The valve and valve seat of the delivery valve are paired. Whenever replac: a new gasket. necessary, replace them as a pair Ne ig. 4-145 Installing the \ pact ig. 4.148 el Heed Plug Valve sering lam4-61 Caution: When installing the solenoid, never forget to install the piston and spring. Fig, 4-148 Installing the Solenoid = nn ® 4-149 Assembling the Governar Sleeve fly weight replacement is neces: sary, replace all four weights as a set. Fig. 4.150 Assembling the Hlowing parts: &j& 1 Governor shat 2 Adiusting washer Caution The governor shaft threading is left-handed,rust weight holder with a thickne the standard is nor satis y changing the adjust washer shickness, Thrust cieerance: 0.15 ~ 0.3% (0.0059 - 0.0 {Clearance on entire circumferenc sinner in YE fe be thrust clearance Adjusting washer type Weigt ho! Fig. 4-153 Measuring the Thrust Ciaarance (6) Adjust dimension L from the governor TTT 9 the pump housing Caution The governor shaft threading is left-handed, Fig. 4-184 Dimension LCaution: The lock nut adopts left-handed screw, Caution Install the control spring so that the open end of the hook is directed as shown in the figure at right Fig. 4-157. Installing the Governor Cover (1) nor saring and damper and hook Caution 2 Pay attention to the go nor spring seat installing position Use a new governor cover gasket, ording to the si post compensa ed 21s fully covered with Rre(oerrel4-64 ADJUSTMENT (2J) Adjustment Sequence 1, Inspection and preparation before test 2, Running-in 3. Temporary adjusiment imp internat pressure adjustment 5. Overflow rate inspection 6. Timer adjustment 7, Fullsload injection voiume aaj 8. Adjustmer of injection vaiume at 9. Full-load injections volume check 10. High speed lever setting 11. Low speed lever setting Inspection and Preparation before Test 0~Ska/em* (0 ~85 psi) 1. Feed pump 2. Fuel filter 3. Adjusting valve 4. Pressuce gauge or Teed pressure measurement) Fig 4.160 Fig. 4-189. Pump Adjustment A Valve opening pressure 0 ~10 kofem? . (0 ~ 142 psi) (B) 143. ~ 155 kalem? 7 (2062 ~ 2208 psid 5. Prassure gaug) al pressure measurement! 6 Nozzle and nozzie holder 7, Measuring eylinger B Fuel tank 8 Piping Diagram for PCaution Do not mistake the overflow screw and inlet screw, The overflow screw is marked “QUT” Fig. 4.163 Connecting the Pressure Gauge and Gvertiow Hose i4-66 (4) Aopiy 14 Fig. 4-168 Applying a Voltage to the Solenoid 1. Stabitize the fue! perature at 40 ~ 45°C (104 — 113°F) E t the fead pre: Run the pump ata lov been bleed thraugh th air in the namber has, 4. Fix the adju he FULL position by pulling with a spring, Gradually raise the pump speed. After checking u from the pump surface to enabl curs at 1200 rpm, wipe oil of 5. Operate the pump in this state at 8 in the pump. Caution: If any abnormality such as oil leakage, injection failure or abnormal noise generati this operation, immediately turn the switch off and inspect the pumo. nis found during 6. After setting the key groove of the drive as cE ft at the angle shown in the figure at right extract the delivery valve from Make sure that the fuel comes out when 3 feed pressure of 0.2 kgf applied, sha Caution: the fuel does not come out from cylin C, correct the cam plate installation because it is taulty (180° opposite} Fig. 4.168 Drive Shaft Key Groove Position4-67 Temporary Adjustment (Lever at FULL position) mporary adi I-load standard tion volum Measure the injection volume at a pump soeed of 1000 rpm. If the standard is ni ied, adjus: turning 1 Standard (0.46 Fig. 4-187 Adjusting the Full-ioad Standard Injection Volume Temporarily 2. Temporary at high speed lever -- setting Measure the injection volumeat a pump speed of 1300 rpm. If the standard is not satisfied, adjust maximum speed set screw. Standard: 1.8~34 @ injection volume by turning the Fig. 4-168 Adjusting the High Speed Lever Setting Temporsrily Pump Internal Pressure Adjustment (Lever at FULL position) Measure the pressure at each specified sozed Standards Pump speed Fig. 4-169. Adjusting the Pump Internal Pressure Caution Carefully prevent overdriving, lt Repla fe the standard,4-68 Overflow Rate Inspection (Lever at FULL position) 1, Measure the over! of 1200 rpm Standard: 200 — 460 ec/min (12.2 - 27.4 ev-in/min.) rate at a pump speed Caution: Always use the overflow screw attached to the engine imer Adjustment (Lever at FULL position) Remove the cover on the high pressure side (not installed with 2 soring) of the timer Install the timer measuring device (NIPPONDENSO part No. 95905-10110) and make zero adjust 2. Messure the timer piston stroke for e: specified soeed Standards Pump speed Piston stroke | wpm | mm (in) | ~0.8 (0.0039~0.031) 06-14 (0,024~0.055 1.2~2.0 (0.047~0.078) 2.0 (0.047~0,078) all be 0.3 mm (0.012") or if the standard is not satistied, remove the timer cover (the side installed with the spring) and make adjustment by changing the thickn 0 both sides of the timer soring Caution © Washers shall be inserted on both sides of the timer spring 2 Increasing the washer thickness reduces the stroke and vice versa Fig, 4-171 Instalting 170 -Full-load Injection Volume Adjustment (Lever at FULL position) Measure the injection volume at a pump speed of 1000 rpm, If the standard is not tisfied, make adjustment by turning the full load set screw. Standard: 7.9 — 8.1 cc/200 st. 1 cyl. (0.48 — 0.49 cu-in/200 st. 1 cyl.) {Deviation: 0.4 ce (0.024 cu-in) or tess} Adjustment of Injection Volume at Start- ing (Lever at FULL position) speed of 100 com | Standare: 120 18,0 60/200st. 1 ey ~ tH | = 0.91 eusin/200 st. 1 ev) ( Baa | (Deviation: 0.8 1 —— \) | men: by changing Fig. 4-178 Governor Sleeve Plug Increasing dim v2 plug by 0.2 Injection volum cu-in/200 st.) sion L of (0.007 1.6 cc/200 st (0.098 Governor siee ; ; 7 . 1 Dimension L ' Dimension L 1 7387-54018 4.3 (0.169) 5 | 22787-54019 45 (0.177) 5 | 22787-64020 47 (0.185) ! | 49 (0.193) T ery valve spring -171=4-70 Full-load Injection Volume Check 1. Check that volume under the ing table satisties the iandard, e full-load standard injection IAditions in the follow- Hf not, make adjustment by turning the full load set scre Standard |] Pump | inietion voium | povaon keer | Soret | iSofter” | Deviation oh rpm (cu-im/200 sth ~ = 7a~a oa latte elena Fig. 4175. Adjusting the Fultoad Standard injection woo | 22~102 | 08 080~062) | 10.03) position) : ao | 74~80 os 1045~0.48) | (0.03 1m | 80~8e | os | I toas~a.sa) | coos | zl does not sais the standard, | spring or insoe instatlation status. High Speed Lever Setting 1. Adjust the injection volume under Standard YY turning the maxin the delivery valve and valve ct the delivery valve gasket the conditions in the following table. Fig. 4.178 um spe Adjusting Lever Angle Lever angle | ion volum (eu:ia/200 st} Remarks 2.0~3.2 (0,12~0.19} eee Lo- lever setting +2057 + (FULL { 1250 _38~8.0 (0.34~0.48) ~ i - Position) 1400 | ss (0.037 or less) - | Reference Tightening the volume, Fig. 4.177, High Speed r SextingLow Speed Lever Setting 1, Free the adjusting lever. 2, Adjust the injection volum standard T injection volume | Leverangle | Purespees | Inaction sume Deviation | emares mere fom (cu-in/500 st} cc (eusin) | eres 18° 3.0~5.0 (0.18~0.30) 1.0 (0.061) | Low speed lever setting DL 2 | 10.0 min, (0,61 min) - Confirm y Boston) ao «| OB mex TOSI max) Conn | Reference Tightening the screw increases the injection volume Fig. 4-178 Low Speed Lever Setting Check after Adjustment on completion af adjustment, cut off voltage supply to the fuel cut solenoid and check that injec- tthe pump sp 100 rpm.) jen the IOLE and FU .ositions 2. The lever angle shall be 38° 5° Seal the full load set sc and maximum4-72 ADJUSTMENT (2J-T) Adjustment Sequence Inspection and preparation b Running.in Airtigh Temporary Timer adjustmei Fig. 4-179 Pump Adjustment Full-load injection volume adjusiment Caren sona Adjustment of injection volume at sta — Reference: —— | The photos of the injection pump in this | section show the ACSD (advancer for starting) other than the boost compensator | | as an additional device. Since the ACSD is | not installed in the 2J-T engine vehicles. 13. Hysteresis inspection its explanation is omitted. 10. Fullsoad minimum injection volume adj a 11. Boost compensator characteristic adjustment 12. Boost compensator characteristic inclination adjustment eck st 14. Full-load injection volume ct 15, High speed lever setting 16. Low speed lever setting Inspection and Preparation before Test a GD Ao~t0kalem? verve opening oresue «| 0 ~6 kg/cm? (0 ~85 psi) Gio ~ 142 psig) 145 ~ 188 kslem? | t ~ (2062 ~2204 psi) | sl] |c|| Jo | 1. Feed puma 5. 9. Ovartiow screw 2. Fue filter Ifor internal pressure measuremen") Reesor | 3 Adjusting vaive Nozzle and nozzie holder Manometer race es 7. Measuring cylinder or feed pressure mesturement) 8B. Fuel tank | Fig. 4-180. Piping Diagram for Pump Adjustme>: -14-gauge (f 1) Ce et hose, Caution: Do not mistake the overflow screw and inlet screw, The overflow screw is marked "OUT" Fig. 4-184 Connecting the High Pressure Pipe4-74 (4) Apply 14V to the fuel cut solenc Fig. 4.183 Applying a Voltage.to the Solenoid 5. Provide a manometer Provide a ry manometer capable of measuring 1000 mmHg to measure the pres: sure applied to the diaphragm chamber. Connect the manometer, boost compensator Port and vacuum pump of the test bench by a three prouged hose The vacuum pump handle shall be turned I fully counterclockwise. Fig. 4-186 Setting :pe Manome: Running-in 04 — 13°F} 1. Stabilize the fuel temperature at 40 ~ 45°C ( 2. Adjust the feed pressure of the pump tester of 0.2 kg/ci 3. Run the pumo at 2 low speed (about 300 rom) and make been bled 1 the overflow pipe 4, Fix the adjusting lever at the FULL position by pulting with a spring Gradually raise the pump speed. After checking thar injection occuss from the pump surface to enable ail lea Caution: If any abnormality such as oil leakage, injection failure or abnormal noise generat this operation, immediately turn the switch off and inspect the pump. on is found duringhown extras ry val Make sure that the fuel ¢ feed plied Caution: If the fuel does not come out from cylinder C. correct the cam piate installation because itis faulty (180° opposite). Airtightness Test of Boost Compensator sure ndard: 10 seconds {Min Temporary Adjustment Lever at FULL Position) Temporary adju: full-load standard injection volume Anply a positive pressure of 400 mmHg and measure tion volume at a pump ard is. ne turning the speed of 900 rp satisfied, mai full load set Standard: 9.0 — 10.0 c¢/200 st, 1 ey (0.55 ~ 0.81 cu-in/200 st, 1 cy.) Temporary adjustment of high speed lever setting Apply a positive pressure of £00 mm sure the inj and tistied, make adj ment by turning the maximum sp tandard: 5.0 ~ 9.0 ec/200 st, 1 cy! (031 of 1000 mmb Ig t0 the boo: ‘< { Rh +o ‘9. 4187 Drive Shaft Key Groove Position Plain Fig, 4188 Adjusting the Fulloed Standard injection Volume temporarily Fig 4189 Adjusting the High Speed Lever Setting Temporarily4-76 Pump Internal Pressure Adjustment (Lever at FULL position) 1, Measure Fig. 4-190 Adjusting the Pump Internat Pressure Apply 23 - 4mm (0. ‘ound rod to thé give a I observing the pressure gai 7 tap to de Caution Carefully prevent overdriving Overflow Rate Inspection (Lever at FULL position) Caution Always use the ov ‘the engine. attached to Fig. 4-191 Measuring the Overflow Ri Timer Adjustment (Lever at FULL position) 1. Remove the cover an the high pressure sid (not ins Install the timer meas (NIPPONDENSO part No. 9 make zero adjustment, led with a. spring Fig. 4.192. Installing the Measuri4-77 2. Measure the timer piston sirake at each specified spese. Standard Pump speed | Piston stroke rpm i mm (in) 600 | 0.1~0.8 (0.0039~0.031) 750 | 0.6~1.4 (0.024~0.055) 900 | 12-20 10.047~0.078) 1100 | 1.2~2.0 10.047~0.078) (The hysteresis shall be 0.3 mm (0.12") or less. If the standard is not satisfied, remove the timer cover [installed with the spring), and make adjustment by changing the thickness ‘of adjusting washers on both sides of the timer spring Caution: ‘© Washers shall be inserted on both sides of the timer spring, © Increasing the washer thickness reduces the stroke and vice versa. Full-load Injection Volume Adjustment (Lever at FULL position) 1. Apply a positive pressure of 400 mmHg. Measure the injection volume at a pump speed of 900 rom. If the standard value is not satisfied, adjust by turning the full-load set screw. Standard: 9.3 — 9,5 cc/200 st, 1 cyt. (0.57 — 0.58 cu-in/200 st, 1 cyl.) (Deviation: 0.4 ce (0,024 curin) or less] Adjustment of Injection Volume at Starting (Lever at FULL position) 1. Measure the injection volume at a pump speed of 100 rpm without applying a posi- tive pressure Standard: 12.0 ~ 15.0 cc/200st, 1 cyl (0.73 — 0.91 cu-in/200 st, t cyl.) (Deviation: 1.0 ce (0.061 cu-in)] 2. If the standard is nat satisfied, make adjust ment by changing the governor sleeve plug Increasing dimension L of the governor sleeve plug by 0.2 mm [0,0079") decreases the in jection volume by 1.6 cc/200 st (0.098 curin/200 st} 170 Fig. 4-193 Timer Adjustment Timer adjusting washer types ‘Change the washer thickness. T Washer part No. ae (22624-54010 0.2 (0.0079) 22621-54010 05 (0.0197) 22622-54010 1.0 (0.0394) Full load ser screw. Fig. 4-194 Adjusting the Full-oad Injection Volume Fig. 4-195 Governor Sigeve Plug4-78 Governor standard, reo! Full-load Minimum Injection Volume Adjustment (Lever at FULL position) 1, Measure the injection volume at a gump seed af 900 rom w tive pressure. If the st 2 adjustment by turning the stop si of the boost compensator. Standard: 7.1 — 7.7 jour apptying lard is not satisfied, 00 st cu-in/200 st, Note: © Tightening the stop injection volume If adjustment to the standard by the stop screw is impossible, the boost compensa: tor shim thickness adjustment may be faulty screw increases the Boost Compensator Characteristic Adjust- ment (Lever at FULL position) 1. Apply a positive pressure of 100 mmHg a measure the injection volume at a pump speed of 900 rpm. If the standard is not satisfied, make adjustment by turning che spring guide bush Standard ng ce/200 st, 1 cyl (The hysi (0.018 cu Note: For the overflow fitter and turn the spring guide bushing adjustment, remove with a screwdriver applied to clockwise turn from increases the injection volume If adjustment. in this ways is insufficient, check the guide bushing installing direc tion or replace the spring. Fig. 4-196 Adjusting the Fulload Minimum Injection Vou Fig, 4-197 Adjusting the Boost Compensator CharacteristicBoost Compensator Characteristic Inclina- tion Adjustment (Lever at FULL position) | Actually 1 | measured 1. Apply a positive pressure of 200 mmHg and g, ue measure the injection volume at a pump 32 eee z2 = Increase the speed of 900 a! 221 Setting spring constant Standard: 8.7 ~ 9.3 c¢/200st, 1 cv (0.53 — 0.56 cu-in/200 st, 1 cyl.) | | | | | | | | | | Pe boost compansator spring with a one having a different soring constant. ae Lnevuaity —~ Sorin Constant Boost compensator spring tyo: measured valve Part No. |__Soring constant K pe 22174-21910-71 | 20 22172-21910-71 | 2.2 (Ordinary) Fig. 4-198 Adjusting the inclination of the Boost Gompensator Characteristic 2732191071 | 24 Caution: After replacing the spring, make readjust- ment according to steps 3,8 ~ 12 in the Adjustment Sequence. Hysteresis Inspection (Lever at FULL position) 1, Compare each injection valu ‘his order at a pump speed of 900 rom with each inject raised in this order for positive pressures 200 mmHg, 100 mmHg and O mmHg lowered in n volume for the same positive pressures Each injection volume for ng boost pressures and allowable hysteresis, Pump speed T Boost pressure | Injection volume Hysteresis ro" ming 02/200 st (cu-in/200 st) | c0/200 st (cu-in/200 si) 00 0 | 71~7.7 0.44~-0.48) | 900 100 78-84 (048-081) | O3or less (0.018 or 900 j 200 8.7~9.3 (053-056) | 900 | 250 {| 92~9.6 10.56 ~0.59) If the standard is not satisfied, check sliding status of each movable part of the boost compensator and existence of oil Caution: Each measurement shall be made after one reciprocating motion of the adjusting lever between the IDLE and FULL positions. -181 =4-80 Full-load Injection Volume Check 1. Check if volume satisfies the standard under the fol: lowing condi lard is not satisfied, make adjustment by turning the full toad set sc the fulload. standard injectia jons, If the st Stani angle 120° 25° (FULL position} 2 If the deviation does nat satisfy # rep \e standard ce the delivery valve and valve spring or inspect the installatior ne delivery valve gasket High Speed Lever Setting 1. Adjust the injection votume by turning the maxim 7 the table under the condition: below. Standard Full load set Plain screwdriver Fig. 4-199 Adjusting the Fullload Standard Injection Volume sd | Boost pressure | Lever angle rpm {| mmHg 9c/200st, 1 cyi.(cusin/200 st) 1250 700 Baa o~0En z cpess aersecrd [500 700 20-3210 12-0 = [eontimanon postion) | 1400 400 | OB or less (0.37 or iss Confirmation Reference Tightening the screw reduces the injection volume. Sete Fig. 4.201 Serving che — 182