INJECTION PUMP ASSEMBLY (Diesel Kiki-Bosch oan ‘ Description . . g Injection pump Altitude compensator {Engine on vehicle) . Disassembly ... Assembly Testing of injection pump Feed pump .. Timer Fuel filter . Service data and specifications . Special service tools INJECTION PUMP: ‘ASSEMBLY. eee (Diesel Kiki-Bosch VE-type) . Description : Injection pump .. .. Disassembly (Without high altitude compensator)... Disassembly (With high altitude compensator) ENC INE! FUEL CONTENTS Inspection EF. 2 Assembly EF 2 Testing of injection pump EF 2 Service data and specifications Special service tools ........--... EF 4 INJECTION PUMP ASSEMBLY EF.6 — (C.A.V-D.P.A. type) EF. 9 Description EF-13 Injection pump - EFAB Feed pump EF-19 Fuel filter: EF21 Service data and specifications EF-22 INJECTION NOZZLE ASSEMBLY . EF-42 Removal and installation . For Diese! Kiki . EF44 ForCAV-DPA. . EF-4g Service data and specifications Fag Special service tools CRANKCASE EMISSION CONTROL ER47: - $78 a La mi al £2 consa steve pagan a) "of f Cg asembly t\) ee : ass 5 ORD pHi : 07 Bee is ~ PREPARATION fuel injection pump, clean all dust © Be careful not to bend or seratch and dirt from its exterior. ‘@ Clean work bench completely, re ‘moving all foreign matter. ‘¢ Collect only those service tools ne- cessary for disassembling and reas- sembling. fe Before performing disassembly and adjustment, test fuel injection ‘pump and note test results except ‘when testing is impossible. ‘¢ Prior to beginning to disassemble 1pK57920032 xsr6012 4 DK57915010 EF-6 any parts. © Be careful not to mix parts of dif ferent cylinders. Special tools for disassembling and re- assembling fuel injection pump 's717080000 | (oxs7916832) ——pxs7931612 ~—pKs7921012INJECTION PUMP ASSEMBLY (Diesel Kiki-Bosch Reference table —y 1000 ‘Atmonpheie 1013 v3 | #66 | 800 | 733 | 667 pres P cioi3, | a.000,| «933, | «66. | (600, | 733, | 667, Paar, "0, | 750,"| 700. | 630, | so0, | ss0, | soo, rote) 2993 | 2953 | 2756) | 2588) | 2363) | 2168) | 1965) “Amount of oosning ofcap mut (No-orR | 9 Jo.1~03 |04~08 J09~1.3 |1.4~1.8 |1.9~2.3 }24~26 fap aut 2) Expedient method should be loosened, according to alti Determine how much the cap nut tude above sa level Approximate altitude | 0 20 700 | 1,300 | 2,000 | 2,700 | 3400 | may | @ | 299 | 2.297 | 265) | cs62) | 889 fats ‘Amount of osening atespautNoof | 0 foros Jos~os losm1s |14~18|19-23 | 24-26 evolutions of cap nut) 5. Mark cap nut indicating the num- ber of times cap nut should be rotated according to altitudes in which ve- hicles ae to be operated. 6, Tighten lock nut, 7. Install diesel pump controller rod. Ensure that bolt comes into contact with injection pump lever. If it does not, loosen the bolt and readjust. BLEEDING FUEL svSTEM {Eoinn on vehicle! aioe nel at sey win Injection pump Is removed oF eipatetfesrt 1. Remove the cap tht covers the priming pump @). 2. Tum the priming pump @ counterlockwe 3. Lacon thei vent serwa ©) 4, Move the priming pump @) up tnd down nth no further red eset eek ved area) 5. Tighten the ar Yrt srowe D: 6 Pou end for the priming pump choke 7. Intl the ap. EF-5 WARNING: Wipe off fuel around engine. If engine will not start, loosen injec: tion tubes at nozzle side and crank engine until fuel overflows from injec: ton tubes, Tighten injection tube flare nuts. IDLE AND MAXIMUM SPEED ADJUSTMENTS Refer to Section MA for these adjust- mentsINJECTION PUMP ASSEMBLY (Diese! Kiki-Bosch 1. Drain injection pump oil 2. Attach injection pump with Tool. 6. Check camshaft end play. Refer to Inspection. 7. -Remove mechanical cover, diaphragm cover, governor iaphragm, flyweight and governor housing, Refer to Governor for removal 8, Remove plug, 3. Remove feed pump and cover epnta, plate. 4. Check backlash between control 10. _ Remove Tool DKS7931210 by rack and control pinion. pushing tappet_— with Tool Refer to Inspection. DKS7921012. s. (1) Temporarity install timer to injee- CAUTIO tion pump. Be careful not to damage housing plug (2) Turn timer until tapper is raised ale threads, line typed 12. Remove plungers together with lower spring seat with Tool. cauTiot Lay out plunger and plunger barrel im order in a pan of kerosene or sol vent. Do not touch plunger with hand. DKSTORAI 13. Remove plunger spring, upper spring seat and control sleeve assem- bly, When disassembling contro! sleeve assembly, put matching mark. to TDC. for each cylinder and then install Tool between tappet adjusting bolt and nut. If Tool cannot be installed, loosen tappet adjusting bolt eerian 11. Withdraw tappet assembly with Tool DKS7931612. from camshaft chamber by loosening Tool DKS7921012. 14, Remove lock plate. 15. Remove delivery valve holder and then remove delivery holder spring, and delivery valve stopper.INJECTION PUMP ASSEMBLY (Diesel Kiki-Bosch i o 19, Remove control rack guide serew and then draw out control rack. reals ing in Tool 16, Remove delivery valve by thread- it from below 17. Remove plunger barrel by pushing sereaia| control rack. 18, Remove cap and bolt and nut on. S| . [9 = ee |_| Fieezasal INSPECTION Pump housing 1, Inspect for damage, cracks, ete. If excessively damaged, replace it with a new housing 2. Check plunger barrel drum surface for proper contact with plunger barrel seating hole. Also, check for damage ‘or cracks. If faulty, replace with a new plunger and plunger barrel. 3. Measure tappet to housing clear- ance. If worn beyond wear limit, re- place tappet or housing ‘Tappet to housing clearance (A-B): Limit 0.2.mm (0.008 in} F728 Camshaft 1, Measure cam profile for uneven or excessive wear. If excessively or un- evenly worn, replace camshaft with a 2. Check for damage, cracks, ete EF-8 ine type) If excessively damaged, replace it with a new one. 3. Measure camshaft end play by pushing camshaft from timer end so as to move camshaft in shaft direction, Camshaft end play Standard: ‘SD 4-eylinder 0.0.02 mm (0 - 0.0008 in) 033 0 - 0.03 mm (0 - 0.0012 in} Limit: (0.1.mm (0,004 in) If camshaft end play is over limit, adjust as follows: (1) Remove bearing inner race from camshaft (2) Based upon end play measure- ment, increase or decrease adjusting shims. Use the same shim thickness on each end. (3) Reinstall bearing inner race on camshaft. Bearings Check for wear or discoloration. If faulty, replace with a new one. Plunger and plunger barrel ‘The operation of the plunger should bbe checked based on the results of fuel injection volume measurement. Oibtightness check 1. Thoroughly clean plunger barrel in clear kerosene or solvent. 2, Tilt it to approximately 60°. ‘Then, let plunger slide.down through barrel, making sure that plunger slidesINJECTION PUMP ASSEMBLY (Diesel Ki smoothly. Repeat this procedure by turning plunger to various positions, making sure that plunger slides ‘smoothly in any of the positions. ¥ i foe When replacement is required, re place both the plunger and plunger barrel asa set. Delivery valve ightness check 1. Thoroughly clean delivery valve ‘nd delivery valve seat in clear kero- sene or solvent. 2. Place finger over lower pa:t of valve seat, lightly depress delivery valve with your finger tip, and make sure ‘that valve springs back when released, If valve falls to valve seat, it is not ‘operating properly due to excessive piston wear. If faulty, replace with a new valve and valve seat assembly, Adjusting bolt head recess wear lien (0.20 mm (0.0079 in) Roller end play limit: 0.20 mm (0.0079 in) > [if Recon Push Nf End play A Control rack and control sleeve assembly 1. Inspect control rack for bending and damage If faulty, repair or replace with a new control rack, as required. 2. Measure control sleeve to plunger lug clearance. If worn excessively, re- place control sleeve or plunger, as re- guired. Contro! sleeve to plunger lug clearance (A-B): Limit (0.12 mm (0.0047 in) Spring Inspect plunger and delivery valve springs for damage and squareness. ASSEMBLY Clean parti thoroughly and apply 4 thin coat of engine oil to rotating ‘and sliding parts. ‘Assemble injection pump in the re- verse order of disassembly. ‘Note the following items. 1, Set plunger barrel in position, with hole in barrel aligned with dowel pin of housing Alien QQ i. Tappet Inspect tappet, roller roller bushing, and pin for wear or damage. If faulty, replace with new components, as re quired. 3. Measure backlash between control rack and control pinion, Backlash between control rack and control pinion: Limit (0.30 mm (0.0118 in) EF-9 2. Install delivery valve with new gasket, setting it into position by tapping lightly with Tool. Neweastet | UA \ \ me mys tae sping \ \ senbiy \ \ 5 2 Gana ee SR \ shim ®) || \ saws MCh A) | Nag pel etree , a 2 \ speed adining Seas te) Fortedtiak belt oF = Contato = Gasket * Always replace Preamatic * atways replace cr7408 EF-11INJECTION PUMP ASSEMBLY (Diesel Kiki-Bosch 1. Attach injection pump with Tool DKOS794002 (Universal vise) and then remove feed pump and cover plate 2. Install Tool between tappet ad- justing bolt and nut Refer to Injection pump for tappet holder installation. 3. Remove diaphragm cover, pneu- matic governor spring and shims. 4, Remove diaphragm by pulling cotter pin out with pulling it out from housing. Be careful not to damage the die phragm. 5 ‘@ MZ governor Remove camshaft cap. @ RBD-MZ governor (1) Remove mechanical governor cover gasket, push rod, spring and (2) Attach timer and lock camshaft with Tool ST17080000 (DKS7916- 432). Remove round nut with Tool DK57915010, Jine type) 6. Remove governor housi Inspection Inspect all parts for deformed threads, 1 Repair or replace parts as necessary. jacks, damage, formation, etc Diaphragm Even the smallest hole in it can adversely affect governor performance. Visually inspect the diaphragm for broken surface, and the caulked areas for damage. Replace the diaphragm as an assembly when faulty —————— ss CAUTION: © Do not allow gasoline to be left on diaphragm. © Use diaphragm oil. Springs Check all springs for breakage, fatigue or rust formation. If necessary, replace. ad) toINJECTION PUMP ASSEMBLY (Diesel Kiki-Bosch it Assembly Assemble governor in the reverse order of disassembly, noting follow Do not install plate plug until idle adjustment is made 1. Make sure that impeller isinstalled to the camshaft with flat blade side to- ward governor. (RBD-MZ Governor) tine type) 4. Coat caulking part of diaphragm and governor housing with grease. Be careful not to allow grease To get on 2. Apply liquid sealant 10 new ‘overnor cover gasket, Flyweight round nut 49-59 Nm (6.0 -6.0 kom, 36-43 felb) TESTING OF INJECTION PUMP PREPARATION Injection pump test conditions Apply diaphragm ol to diaphragm. 5. Adjust injection pump with a pump tester. Refer to “Testing Injec- ter s be . eae z Injection s9e30° | 119930 | 179930 | 239°30° | a99P30: Stating | 0 Ey 60830 | 200 | 180%20 | 24030 | 0030 4. Check tappet clearance (3) I specified tappet clearance is not () Set camshaft to T.0.C. with obtained, recheck and adjust pre- Setting tool on tappet and then set stroke nuge sae at “0”. oe (2) Lift the tappet with a screwdriver een ere 1. Remove control rack guide screw and install lock screw to fix control rack on pump housing. and measure tappet top clearance (stroke until the plunger contacts the end of the plunger barrel). ‘Tappet clearance: tAUTIO en ae. ee eee Tighten lock screw by han 0:30 mm (0.0118 in) =a Oa, eet ares ( catio, edu nection Sig. (1) Loowe ok nat of appt (2) Adjust teppet height by ting ie adjusting bolt.=k" i © INJECTION PUMP ASSEMBLY (Diesel Ki (1) Loosen control lamp a 1, Remove control rack guide serew and install Jock screw to fix control rack on pump housing. 2, Set Tool DK0S782601 to control pinion rack (2) When setting tool, push control rack fully toward governor side, and align the “0” ‘on measuring device CAUTION: Tighten lock serew by hand. (2) Place suitable tool into hole in control sleeve and adjust by rotating control sleeve. () Take off diaphragm housing together with governor sprit | Otherwise, “0” position may not be obtained, (3) Pull down full control lever toward fuel increasing side, and check the stroke of control rack. Control rack stroke: I Refer to S.0.S. ry jj 3, Set fuel feed pressure Fuel feed prossure: | 147-187 kPa (1.47 - 1.57 bar, | 1.5 -1.6 kglem’ , 21 -23 psid i 4. i] (1) Measure injection volume for each uw ‘eylinder at rated pump speed and con- trol rack position. Injection volumé Refer to S.0S. (2) Compute allowable unbalance of fuel injection volume. ‘Allowable unbalance = eae : sain en) - (ted plunger oto 100 ‘Mean injection volume Allowable unbalance: Refer to S.0S. 5, Adjust injection volume so that specified injection volume and allows ble unbalance is obtained (3) After adjustment is completed, tightly secure pinion set screw. (@) Remove lock screw from control rack and reinstall guide serew. 6. Install. diaphragm housing and governor spring. GOVERNOR Adjustment ‘a. When making a governor perform Lock 108g 2. Set Too! DK0S782601 to control rack, (1) When setting tool, push control rack fully toward governor side, and align the “O" scale. ‘on measuring device ‘ance test, maintain the pump speed at 500 rpm. bb. Gradually step up negative pressure ‘when adjusting. c. Test and adjust injection timing and injection volume before testing ‘governor. 4. Testing and adjusting procedures for the MZ governor and RBD-MZ ‘governor are carried out in the (2) Pull down full control lever toward fuel increasing side, and check the stroke of control rack, Control rack stroke: ‘More than 18.0 mm (0.709 in) Similar manner, For the RBD-MZ governor, ‘mechanical unit. high-speed adjustment 3 should additionally be made on the Connect a hose between vacuum pump of tester and governor negative pressure chamberINJECTION PUMP ASSEMBLY (Diesel Kiki-Bosch in-line type) Airtight test 1. Apply a negative pressure of, 4.904 kPa (49.04 mbar, 500 mmHl;0, 19,69 inl1,0) to governor with rack set at position RI lerre2a. 2. Make sute that negative pressure will not drop below the specified value within 10 seconds Negative pressure: 4.904 - 4.707 kPa (49.04 - 47.07 mbar, 500 - 480. mmH,0, 19.69 - 18.90 inl, 0)/ ‘more than 10 seconds If it drops in less than 10 seconds, check the disphragm and replace if Torque mechanism adjustment 1. Check that torque control spring starts to actuate at negative pressure P, and stops at P;. In other words, torque control travel is Ry — Ry Torque control travel: Refer 10 8.0.5. 2. If torque mechanism adjustment is not within the specifications: (1) Remove diaphragm. (2) Add or remove shim(s) (two types) as required until correct torque mechanism adjustment is made. After installing diaphragm, make an aictight test again, or ong control ‘oting satment {Sina aetoating (erstop acrning. Adjusting 2. Gradually increase negative pres- sure. Make sure that negative pressure is Ps when rack is moved to position Re Idle adjustment 1, With negative pressure kept at Pa, turn idle spring screw in with Tool until rack is set at position Rs. ate spring Lock nut 2. Tighten lock nut, 3. Further increase negative pressure. Make sure that negative pressure is Pe when rack is set at position Rs If necessary, replace idle spring as ‘an assembly. 4, Install plate plug, High-speed adjustment Fororque contol vei | (Mechanical governor section): ee Only RBD-MZ governor RERERT RE RI 1. With negative pressure kept in rasa erase] condition Ps, increase pump speed, ‘heck Apply Pavenate gs point premire & ‘Se point i High-speed adjustment = (Pneumatic governor section) é eS Smoke sesrew adjustment 1, inceate aagatiea peecie. Atpet |p With no negative pressure applied, governor shim until there is balanced | adjust the smoke setscrew so that the condition between rack position R2 | 5 rack is set at position Ru ‘and negative pressure Ps: EF-17INJECTION PUMP ASSEMBLY (| 2. Adjust adjusting bolt of governor spring so that pump speed is Ni when rack starts to be pulled from R2 If above adjustment cannot be ‘made properly by means of adjusting bolt, add or remove mechanical go- vvernor spring shim(s). 3, Increase pump speed, and make sure that pump speed is N2 when rack is set at point Re If pump speed is within specified range, replace mechanical governor spring and readjust. 4. Further increase pump speed, and make sure that rack is set at point Re when pump speed is N3 ‘a If rack is not property set at posi tion Ro, check for wear on partis) between flyweight and push rod ‘and for proper assembly of pump housing. b. If necessary, roplace push rod. FEED PUMP ‘After installing feed pump, bleed air from system. Test Standard fuel feed volume ‘The volume of fuel displaced by the feed pump is more than 300 me (10.6 Imp f 02) for each 15 seconds at 1,000 rpm, ‘The discharge pressure is more than 157 kPa (1.57 bar, 1.6 kg/em?, 23 psi) per 30 seconds at 600 rpm. Pump performance test 1, Connect a pipe to intake side of feed pump, and set pump so that fuel ‘ean be sucked up from fuel evel 1.0 m (G3 ft) below the pump. 2. Operate priming pump at 80 strokes per minute, and make sure that fuel ean be sucked up within 1 minute Aitightness test 1, Stop'up fuel feed pump discharge port and apply 147 to 196 kPa (1.47 to 1.96 bar, 1.5 to 2.0 kg/em?, 21 to 28 psi) of air pressure to intake side of pump, 2, Immerse pump in kerosene (light oil) and make sure that no air leaks from any of pump connections. If ‘bubbles larger than one grain come from fuel feed pump housing or push ‘od joint continuously, replace oil seal at push rod or push rod. Replace feed pump assembly, if necessary. EF-18 type) INSPECTION | mining ume p une tect pnt cbse ee gg! eee smrint QB reed pump 3 Lon asemby as Pie int bot Feed pump housing 1. Check check valve seats. If they fare damaged or excessively worn, re- place housing 2. Check push rod hole. If hole is excessively worn, replace housing, Check valve and cheek valve spring 1, If seat of check valve is excessively wom of scarred, replace check valve with a new one 2. If check valve spring is damaged oor permanently stressed, replace valve spring, Piston and piston spring 1, If periphery of piston is exces- sively worn or scarred, replace piston with a new one. 2. If piston spring is damaged or ‘weakened, replace valve spring.INJECTION PUMP ASSEMBLY (Diesel K. ine type) ‘Tappet assembly 3. Remove timer assembly by 4. _Install timing gear cover with new reading in Tool sket sealed i Teed threading in Too! a If periphery of tappet is worn or scarred, replace it with a new one. 2. Tappet roller If periphery of t cessively worn or with a new one. ADJUSTMENT 1. Install stroboscope, using cover | late bolts, so that synchronizer lever attachment is applied to tappet. 2. Operate fuel injection pump, turn “ON” switch of stroboscope illuminat ing dial (angle scale) on flywheel, and Roller to pin clearance: tim naked gsi Tesarg band” oa 8.30 mm (0.0178 i) reemerged Tower ren pe cue termes) / If tester does not have a dial (angle Mor ime as ES a tt es Gl 148 mm (0587 in) {1 Attach dl 10 ther couring sl pe St ace oat ISTALLATION (2) Operate fe ection pump aod 1. Align crank pulley and front cover tum stroboscope “ON” so as to marks $0 that No. I piston is at top iluminate dial. pee TIMER eMOVAL eee Rae A serena] S 2. Mesh injection pump drive gear 3. If advance angle is not within \| with idler gear at Y-mark, and then specified range, adjust by changing align gear to key way of injection timer spring shims. pump camshaft while turning crank pulley. When injection timing is retarded, decrease shim thickness. 'b. When injection timing is advanced, increase shim thickness. Timer advance cure: JA > Refer to S.D.S. 2. Remove timer round nut. Ke Adjusting K 3, Secure timer assembly with lock | shim ?” washer and round nut. @ : Round nut: ch 59-691Nm 67738 (er igeiartereay Fiyweight holder areok EF-19INJECTION PUMP ASSEMBLY (Diesel Kiki-Bosch type) DISASSEMBLY ie with flyweight holder hole positioned 2 ae al 98-177 Nam (10-18 kgm, 72-130 P41) Drive gear Timer Mange © Flyweight 4. Remove timer flange by prying with lever while pressing spring with ‘Tool DKS7916432. Place timer assembly on Tools base pin, "Remove injection pump drive gear. INSPECTION Check all parts for wear or damage. ASSEMBLY 1. Set flyweight holder on Tools with flyweight holder pin hole posi tioned on base pin. 2. Apply grease to flyweight holder pin and flyweight hokler hole 5. Install flyweight and insert Tool ‘under timer spring, positioning spring on flyweight, DKSTORI7O “Timer spr px57932020 5. Remove timer spring, adjusting 3. Remove nut, lock washer, lock shim and flyweight. plate, adjusting shim and thrust washer after unbending lock washer. 4, Insert suitable adjusting shim into hhole at pin part of timer flange. 5. Cover timer flange to flyweight holder by matching notch of flange ‘and key groove of flyweight holder. Adjusting shimINJECTION PUMP ASSEMBLY (Diesel Kiki-Bosch in-line type) 6, (1) Turn Too! DKS7916432 in direc tion to compress timer spring, thread in Tool DKS7924190, and then re- move Tool DKS7932020, DKST9I6A2 x57924190, A, : (2) Using a lever, insert timer spring into flange hole, thread in Tool DKS7924190 all the way and install flange in its proper position. ‘Make sure that spring is fully seated in holes in flange and flyweight holder. 7. Adjust flyweight holder and flange clearance. (2) Install thrust washer, lock plate and adjusting shims, and completely tighten them with nut. Nut 98-177 Nm (10-18 kgm, 72-130 ftb) Lock plate and thrust washer clearance: (0.02 - 0.10 mm (0.0008 - 0.0039 in} (2) Measure lock plate and thrust washer clearance. If the clearance is not within specifications, adjust with adjusting shim. 8. Align “O” mark on di with notch in timer flange, drive gear. FUEL FILTER Bleed air from fuel system after in- stalling fuel fitor. Test Overflow valve Attach a pressure gauge to fuel filter discharge port, and check valve ‘opening pressure by operating priming pump. If pressure is not within range of 147 to 157 kPa (1.47 to 1.57 bar, 15 to 1.6 kg/em?, 21 to 23 psi), re- place overflow valve. 147-157 KPa (147-157 bar, 18-18 kg/emd, 21-23 pa From fuel tank F708, EF-21 INSPECTION Overflow vale Tet om ered oay pater .. ene ae ~~ Element Pking Sig Element Check element for clogging, damage, or peeling. If faulty, replace with a now filter element Body and upper covers Inspect body for cracks or damage and examine covers for splits or dam- age. Replace faulty components withSERVICE DATA AND SPECIFICATIONS TABLE OF MODELS AND CORRESPONDING PUMP NUMBERS JECTION PUMP ASSEMBLY (Diesel iki‘ Bosch in. Jine type) INSPECTION AND ADJUSTMENT Injection pump ‘Standard mm (in) |. Linit mm (in) aa ee eee oe ee se 0.020.082 || 9.20 (0.0079) ee rama raung | ent | oH 0620) 16700-V1301 101433-0431 aes mg aot 20082 soo so——stevoovyousa.——‘1ezt.o000 met soon | 08-8082,,| 020100071 fereovetot —jonestanro : ie {eroo.veucs oso eee toss ie caeae nel ae ———eramasaos —rorean oot {Shooceeor —tonestst cerca pee | ocean = 160 ‘$033 16700-06808 101631-9571 ‘trunnion shaft clearance | (0.0008 - 0.0031) oe roocescs —_toresteeno } . — 16700-06811 101631-9660 sD 0-008 ane caminns | fever | 000081 40 —«SD25 16700-78263 1014419040 tend play Se ae. (0 -0.0012) “Gao abasteroorzea—voreeroso | Teroowem00 01431890 onal etiopinon | g,p ooo | 20100018 {eroolesen—toveat 00 {eyooleses fovea. 980 aie Coenen tw som—stevoowmans——‘tonentoeo comet [PO | ton saved |” {reosmeen ——‘oreznsoro Son al lerooieoen—toneatarto ee © aces | amen erooviaes tones a770 DB" | toe een) Fa $025 «16700-78263 ——«y01441040 tin 3 age | 89°30 -00°20 16700-3102 101433-9230 {eam angie) | S033 9° 30° - 60°30" = som wroosmneo ‘foun e700 3eWoo ——torassoW01 Inecien etna tining | 225.236 16700-34W02 101433-9421 (pre-stroke: plunger lift a a ye toch toosee 02825) Temooone) von 1 so23 rea aaa eas | aa | \eeome westarre owe cmon | cum T37008ams0 ———somer 120 lr 16700-54W61 10141-9160, mm {in} - oz oaoan | ver 37801 o.oo) | vera 7802 vanced 0.16 (0.0063) | 16741 37503 Seon exe oa07n | 16741 aoe aa0 oor) | 167 a7e08 sovcover | wera a7e08 EF-22INJECTION PUMP ASSEMBLY (Diesel Kiki-Bosch in-line type) Fates outer diameter 1500501) | 14910587) it oud cate ‘300 me (106 imp fz) or more Within 15 seconds at a pure ‘speed of 1,000 rom. Pumping cape Discharge should occur within one ‘minute (60 seconds with a pump speed of 100 rpm and intake head OF LOmeter (3.31, (0 feed presure ‘The ume required to develop an oil feed pressure of 157 KPa (1.67 bar, 1. kafem2, 23 psi with 8 {eed pump speed of 600 rpm should be within 30 second | ‘Pumping copsety (priming pure) Operate the priming pure at «| rate of 60 to 100 stroker per minute and verity thet pumoing is started within 30 stroker, EF-23 Governor Timer = Thickness Flyweight holder to flange = saree Parts number ert a 0.02 - 0.10 (0.0008 - 0.0039) 0.2 (0008) | 19241 276508 =a e201 | 19241 97808 Tete ee fs 2510020) | 19241 37500 eumate governor (01 :@008) | 16822 37500 sta eure sien 1010039) | 18241 37601 Se ere een oo) | eae arto | | nowranioantnsting | ~o3 earn | va8z2 s7601 1510080) | 19281 a7é02 fe caecials: ness earths 05 ozo) | veaan 37502 20.007 | 19241 37500 = ont as 2 Be ‘0.10 0.0039) | 16826 99007 0.110.000) | 19227 37600 zi . °032,00047) | 16826 99000 (0.2 (0.008) | 19727 37601 aoe ee ‘0.14 0.0058) | 16826 92008 eve eelsne 0.3 (0.012) 19227 37502 shting sien ee eee 0.6 0063) | 16828 s0002 osioo20) | 19227 37509 = oe ———— — —— 0.18 (0.0071) | 16826 99003 1.010039) | 19227 a7608 jeoee me 0:20 (0.0079) 21 0000) | 19229 27500 | 03000118) 0200008 | 19770 97501 ora control sring (050100197) rrr 03,012) | 19229 37602 0510020) | 19220 37603 19(00a8) | 19229 37808 Ful filter Tyee eter ‘ertiow vle opening Bae Standard | Weeriimie, premure etal d om Gn) om in Ps ta, baler? sd : 008-008 oertopinctewance — |, 008-208, | g39 0118)INJECTION PUMP ASSEMBLY (Diesel ADJUSTMENT VALUES FOR INJECTION PUMP TESTER Fuel injection quantity (MZ. (Pneumatic) governor Pump Nos, 101431-9710, 101491-9880, 101431-9430 Pack postion | Pumpspeed | stoke ‘Mean injection volume Allowable Prestroke roe (i) ‘om ro (imp to2) unbalance % re (in| 18 (059) 00 363 -98.3 (128-15) 225 14 (05) 1,700) 95.7-28.9(1.26-1.37) 149 Standard Injection (64-66 (0-23-0201 wolume 108 10.428) 300 [eee isd i ae - 291098 i 1000 165-8.9(0.23-031) aitaoem| \ 9 (0.38) 1,700 62-78 (022-027) v8 Full os ferting | OKPa (0 mbar, (No apply | OmmAa, 200 37.3:08(1.91200021 = negative in aad pressure) +) ndieate values for pur No, 101431-9430, [RBD.MZ (Pneumatic-mechanical) governor Pump Nos. 101433-9230, 101439.9370 Track position | Pumpspeed | ci. ‘Mean injection volume Pretroke rm (in) om ee (imp #122) min 321047) ‘800 26-98 (127-138) Suunderd 11 (0.3) 1,700 354-986 (125-120) 340 volume 7.7 0.303) 300 64-86 (023-030) a8 23008 61028) 1,700 1000 72-88 (025-031) 275. eae Full oad ferting | KPa (Omber, (Wospp'y | OmmAa, 800 37408 (1.302002) negative Oinaad pressure) pump Nos. 101431-9590, 101431-9770, 101431.9910, 101431-9960 Teck position | Pumpweed | sayy ‘Mean injection volume ‘Allowable Prestroke ‘men (i om = me (lm f 02) unbalance % me (i 121047) 800 26.3983 (1.28- 1.35) 225 standard 11043) 1,700 38:7 -989 (126-137) 340 Injection volume re 300 64-86 (023-030) 25 5.210:303) ee ince) 610.24) 1.700 Le (62-78(0.22-0.27) 278 (o.9t +0.0020) Full wad sectng kPa (0 mbar, {Wospety | OmmAa, 800 37.2:05 (1.312002) negative ina pressure) FF.24INJECTION PUMP ASSEMBLY (Diesel Kiki-Bosch indine type) Pump Nos. 101433.0060, 101433-9070, 101433-0260 eck postion | Pump weed | 5. Mean injection volume Allowable Prestoxe men i om kd me (imp thee) unbalance rm tn) 111043) 1.000 307-927 (100-118) 225 sands [101039 1.700 29:7 -32.9(1.05 1.16) 240 injection veume 77 0.303) 300) 64-66 (023-030) a5 62.78 022-027 23:05 610.2 vam) | 10 175 (0.091 +0.0020) 72-6(025-030" Fall twa suing {Wo apoWy 1.000 34:08 (1.122002) - rete pressure) + Tncieate ales for Pump No, 101433-9260. Pump Nor. 10141-9040, 101441-8080 Purp speed eon inicton | anowsbie | Prestoke | Conta eck Fock poston mim i Sarees | cae | eee | tae | gee ae rom ne tae) | unbolonee tn) 356-378 117 0481) 1.900 128 Star injection = (135-132 volume cae 8210320) 3100 sie | 2181008 | sag sa jie oneten | et Fuiond setting a ee 0.0020) Ino soon neaatve | (9 mbar, ammaa, Oinaq) | 0° (1.290.021 = ump Nos. 1016319651, 01681-9571 eck positon | Pumosneed | gyogg | Mats niection volume ‘Allowable Preavoke mm in) rom me timp fez) sunatonce % minh 118 (0457) ‘800 315-995 (0.11118) 225 2:18:00 7 : teas | 190 | 1000 | sa9-4211097- 1.48) “ EOE Pa 300 e486 (020-030 Hs FF.9RINJECTION PUMP ASSEMBLY (Diesel Kiki-Bosch in-line type) Pump No, 10143-9000 Faxeaison | Pomme? | ouaie | Memniniacuon vue “owtie a er me tn oe) vntatnee on ed vistoaes) | ooo oa -067 (132-120) 228 smart [roa.oaas) | 1700 wa-a7a 020-130 * sector [eee ome” [Siow [ow |, [__stsee20-020 as ae 610.24) 1,700 6.2-7.8(0.22-0.27) 175 (0.081 20,0020) alot ting | KP omber, thowsty | ommaa, 00 357008 (1 28:00 2 monroe, | Olah pr rome No, 10161-9600, 1016318660 Rackpmiton | Pumped | auaie J Memninicionvtune “Mowae = mn ad 55 xt tino onsen 8 mn od nace | _ eo Bassas ont t@ 728 sna 2.18005 injecti 1 36.0. + ost ier [toxeen [ge | 10 wezi23-130) 7 easy pace aes @5-05(029-030 us pre No, 016339421 ratpation | remem? | arog | embiecion hime Twat 7 a om in ipo) eee om) suave | vieioasn | a00 36-290 (149-198) 28 neon | ee fume | ABE | a0 ca-05 (028-030) a 231008 Fallows 1,900 ating | 04a Omber, (ooets00020) Monty | "oma, 00 sero (13500) 4 wre’ | Omaad cee EF-26INJECTION PUMP ASSEMBLY (Diesel Kiki-Bosch in-line type) Pump No, 101433-9431 eck position | Pumpspeod | gigs Mean injection volume ‘Allowable Prestroke om tin) om en (lp fz) unbalance % ind Standard | 11.8 10468) 800 ‘94,7 26.7 1.22 - 1.20) 228 injection About 7 F volume ae 300 64-86 (023-030) 16 a 22:05 Full oad : (0.09130.0020) setting | 0 kPa (Ombor, Wo spety | Ommag, 800 3.7105 (1.26:0.02) = ative ina) reese) Pump Nos. 101441-9130, 101481-9170 Rack position | Pumpsweed | sei, ‘Mean injection volume ‘Allowable Preatroke ‘en Cin) rom me (imp fl 02) ‘unbalance % ‘om (in) 12 (047) 1.000 378-398 (133-140) 225 Standard Injection | 11200480) 2,000 369-391 (1126-138) 70 volume _ eel ‘300 — 69-91 1024-032) a5 pee Ful tad (0.0846+0.0020) setting oKPe (0 mbar, (Woapoty | Ommaa, 1,000 38:05 (137:0.02) = negative ina) pressure) Pump No, 101631.0562 Rack position | Pumpspeed | g.i3,, | Maan injection volume ‘Allowable Prestroke ‘mm (i pm rt (imp 02) unbalance % ‘rn ind Sunderd | 10.7 (0420) ‘800 286-308 (101-108) 225 215-005 teaece, About ics (0.0846=0.0020), volume Paar 300 (65-85 (023-030) a5 FF.27INJECTION PUMP ASSEMBLY (Diesel Kiki-Bosch in-line type) Pump No. 101429-0401 Rack ponion | Pomp somed —] cvogg | Mesninictionvtume ‘Alowsbie Preaoxe mm (in) pm seins me (Imp fi oz) unbalance % men tin) nas | 2 a7) 300 367 977 (126-139) 22a 1 injection volume Ae | __ 200 64-86(029-020) a 23:05 Folios 1.900 34 setting | 04Ps (Omber, (0.091:0.020) inooeoly |” Ommaa, 300 36.7508 (1.28:002) = neostive ce) rere) Pump Nox. 1014419120, 101481 9160 Wear nscton rumored | suone |My aonabie | Prestoxe | conto rack a ee ‘om ar a unbalance % | mm (in) | stroke mm (in) sme timp ton) wae 123 (0408) 1.900 128 Standard ineton a 149) volume aoout 69-91 2151005 | je4.147 eFi020 wo | p00 | wae-oan | “8 | “oom | itt 87, 160020) Fo ood aetna one . wosens | _ (0 ure) | mb, OmmAa,O inAa) | 19M (143 1.46) FF-28 aINJECTION PUMP Governor pertormance curve ASSEMBLY (Diesel Kiki-Bosch in-line type) Operate injection pump at 500 rpm, increase negative pressure gradually from lower one. (MZ (Pneumatic) governor Pump Nos, 101431-9710, 101431 9880, 10431-0430 18.832 20,392 (85.32 +3.92, {370 240, 34.28 +1.57) 5.590 16,204 (65.90 :2.9, | 570 230, 2248 +1.18), 5,100 =6.196 (51.00 =1.96,| 1520 +20, 2047 10.79) 4.811 20.206 45.11 +2.94, ‘460 +30, 18.11 +118) Negative pressure 2.649 10,245 (26.48 +2.45,| Pa mbar, 270 +25, 10.83 10.98) mma, ina) aac (2.83, 90, 3.54) o RBD-MZ (Pneumatic-mechanical) governor Pump Nos. 101433-9230, 101433-9401 13.141 40392 113141 +992} 1340 #40, 62.76 21.57) 7.984 20.204 (79.44 +294, 810 +30, 31.89 +1.18) 5.198 +0,196 (51.96 21.96, 530 +20, 2087 +0.79), Pneumatic 4511 +0206 46.11 +2.94] 4460 +30, 18.11 81.18), Negative pressure Pa lnbor, 2.648 20.248 (26.49 +245, rama, inAa) 270 +25, 1063 0.98), ‘About 0.883 (183, 90,54) ° Mecnanic! ‘About 2,260 2,000 +10 Pump speed rpm © FRack position mm (in) ———=— 12 lle spring set 1120.3 mm (0.43 20.012 in) A: 110.05 (0,08 20,0020) aaa a / oa A: Torque cont Spo Mma. (0.31)(043 20.012) (0.55), (059) Mas (sn) a 103 05 (0.08 +0.0020) 73703 1s (020) ° (043) (0.459) 029s "0012, (0.295292) ack position mm fin) J|— Below 3 me (0.11 Imp fi 21/1,000 st. ‘Apply #2 negative presure JPurp No. 101433.8230: Set control rack limit t0.17 mm (067 inl Pump No, 101433-9401: Ser conwel rock mit v0 12. 29mm 7 6 7 (054. 2ogg') aba (oz os) 8.08 121204) Control rod postion mm tin) m= 0010) EF-29INJECTION PUMP ASSEMBLY (Diesel Kiki-Bosch in-line type) pmo No, 1014518770, 1014219980 he Pmatc as or 2039219611 282, mA Seu 40,200.57) te ttorng 75°22 ma (0.205 “21? i Soa 208 894-298 0030, 238811.18) Shoo sot 100196 | — Supt 20710791 | J: 1 $008 004 +0 0020) z wgivepesse 48110200 45.11206[ + Nae setsa tennis “ a Sore o.ze eae 245 | — : se Torqucontal ont rmmacyinds) fae es 088) TN/ one / (3,90, 35) / i ips soe wom 75" (oma), oan a Ns 22) gas ech oe echnit ! iow 3 mt (0.11 tp 10,000. | vo 2.060 er eee ee ' 1,900 139 3 rue dom a 34 € 1 “be oon ans wanes (0.12 “pore! Pur etnies re EF-30INJECTION PUMP ASSEMBLY (Diesel Ki type) Pump No, 101431-9910 12,749 20.392 (127.49 =3.92, 11300 240, 61.18 21.57) 7.748 20.294 (77.48 22.94, 790 $20, 31.10 21.18), 4.904 0.106 (49.04 +1.96, 1500 +20, 198,69 20.79), 4511 10.208 (46.11 +294, 4460 230, 18.11 21.18), Negative pressure ~e 2.648 20.245 (26.48 «2.45, Pa (ber, ¢ 270 +26, 1063 +0.98), mda, ina) pale (83,90, 354) ° Mechanica! ‘About 2,260 2,000 10 Pump speed rpm Pump Noe. 101433-9060, 10433-9260 Poeumatic 12.250 10.392 (122.50 43.92, 1250 +40, 49.21 1.57) 7.061 +0.294 (70.61 22.94, 720 $20, 2835 21.18), 4.904 =0 196 (49.04 +1.96, 500 +20, 18.69 0.79), 4511 20.294 145.11 22.04, 460 130, 18.1 #1.18), Negative pressure Pa mbar, maa, ina) 2.648 10,245 (26.48 +2.45,| 270 #25, 1083 +0.98), ‘About 0.889, (3.83, 90, 3.58) 03 10012, TN _ fete soring set 7.5 °9? mm 0.295 2°"? inp ‘A: 1 20,05 (0.04 0.0020) ‘A: Torque control avel ! V ar, aa! (ex 78° woanaasey (029s 1002, Rack postion mm fin) © LL eset etna ‘Aoply #3 negative pressure, (oa) Fock position mm (in) ht oring ot 75°23 mm (0.205 1297 | A: #2006 04 :0.0020 | T 7 A: Torque control travel 7333 05 oz rey ‘o206°0", ack postion eam (in) © Set control rack limit 10.17 mm (0.87 in) EF-31| Mocnanict Pump speed. rpm Pump No, 101433-9070, Pneumatic Negative prosure Pa (mbar, ‘mma, naa) Mechanica Pump speed INJECTION PUMP ASSEMBLY (Diesel Kiki Bosch in-line type) pees we (0.2 “ote ee oan vs ae Bees rea, 151590 10,204 (55.90 +2.98, 2 o 8.100 +0.196 (51.00 +1.96, |— = Sees pat aetes coca nese n4as248, : oe mentee 7 pare / aaa f-— oo selma Sn ee eerie cieesancn About 2,050 ae Apply P39 negative pressure. zal a vom 8 ower a 4004 eaaegete eck postion mm fin) EF-32INJECTION PUMP ASSEMBLY (Diese! Kiki-Bosch in-line type) Pump Nos. 11631-9551, 101631-9671, mui 13.002 +0382 (12092 13.92, 108 240,280 *189) 9308 10.29 99 6 +294, $58 90,780 "1 18) 5588 10.196 (6.88 «1.96, Sao20,2299 070) Aective pesmi we inter, mma ina) | ® 6 ne 020 030 (ous ack poston mm ia) ee sow 3 me (0.1 mp o/,000 Aout 2300 ‘Aly #9 nase premure 430 a | 2.000 13 2 Pump seed rom Bow 3 6 ne ‘or (02) oasn Pack postion mm tn) ae Nox. 1014919900, 101453.9431 Pomc 12651 1092128551 +392, 1,200 240, 50.79 #1571 tale soring se 7.5 “23 mn (0.295 10°"? jn) 7.551 20.294 (75.51 22.94, | ° ° 770290, 2031 #118) 150426196 49.04 +196, * $00.20, 1300 2070) 4511 10294 45.11 12984, A: 11008 (994 0.0020) 60430, 1819148) Neguive premure 2649 20.285 6 48 «745, a ibe, 77028, 1069-098) — fnarrenee conte oes sma, ina) Avout 0.988 4 (333,90, 3.50 ° 733 Tess 20 75"9 — (oazeinaasy oor (0-295 "0912, Rack position rant (in) =| INJECTION PUMP ASSEMBLY (Diesel Kiki-Bosch in-line type) Mechsnies! Jeo] —2som a me {0.19 Imp 021,000 x. lomneramers | 200010 { vos 2.20 Pump speed rom 1 ° a 708 “oa (028 (0.425) i 4004 frase ‘Rack position mm {in} ————*=_ Set contro rack mit to 17 mm (0.67 in) ‘Pump Nos. 101441-9040, 101441-9050 Pema onus 216 = : tesco st 00°92 on 0306790" (121.61, 1,240, 48.82, 6.375:0,206(63,75:2.94, 50:30, 25.58.18) 4.60940. 196 (46.09:1.96, | _ P, 1470220, 16.50:0-79) [As Torque control travel 2.548:0,204 (26.48:2.94, 20:30, 10.63+1.18) 0,740.1 (0.028:0.008), +.070:0.106 (1079:198, est premure NOHO, 4398079) [eFincerma, ina ° 6 soa (0.24) =e (0.43) toase"2%%, Rack position mm (in) ————— Set control rack 10 14.7 25mm i0.579_9 4,9 i Set contol ak By (0879 Soyo) Mechanical ‘About 2600 f+ ——=f-—— Below Set (0.11 imp 1 02)1,000 suet sooty P, sou premure " 2100530 hep sone ‘om ° TraT0ma0 Rack positon men (in)INJECTION PUMP ASSEMBLY (Diesel Kiki-Bosch inline type) Pump Nos. 10163-9600, 101631-9660, 14.416 20.392 (146.16 +392, 1470 +40, 87.87 21.57) 8.826 +0,206 (98,25 «2.94, 900 +30, 35.483 #1.18), 5.884 £0,106 (58.84 «1.96, {600 :20, 23.62 20.78) 4.318 20.298 (43.15 +794, 4440 £30, 1732 1.10) 2.982 20.245 (29.42 =2.48, 300 225, 11.81 0.98) 1.785 +0.490 (17.65 +4.90, 180 280, 7.09 21.97) ° Mechanics! 2,300 +50) +30 2,000 139 Pump speed rpm ° 0 20012,,, © tae spring sat 8 °°? mm (0.31 “0.01? inh A: 015 +0.05 (0,020 +0,0020) 3 = To7 17 20 an (042191043) Rack postion mm fin) we fo stow 2 me (0.11 tmp f 021,000 st Apply P9 negative pressure Soares Tor “4, (0.232) (a2) (012 7204) amp No. 101431-9500 Peumatie 8532:0.302 (85.32:3.92, 870240, 3425:157) $.590:0.294 (55.90:2.94, 1570230, 22.44+1.18), §.10010.196 (6.100196, 1620220, 20.4720.79), 451130204 145.11 1460230, 18.1195, 72.648:0,245 (26.48:2.45, Nepative pressure ma 270126, 10.6309) wa (mbar, maa, ina) Rack position ram (in) w= Pump No. 101631-9660; Set control rack init x0 16 mm (0.63 in) rs ‘K: 12005 (0.04:0.0020) : A. Torave contol travel ar 1 aT 2 80 (o4ax04s3) 1 r0position mm fn)Mechoriea Pump seed «pm Pump No, 1014339370 Pa imbor, ‘maa. ina) Mechanica ump speed «Pm INJECTI [ON PUMP ASSEMBLY (Diesel Kiki-Bosch inline type) ‘About 2030 ‘Apply P9 negative presure 330 P3 1.900439, — 0s saeael 1 (012) 0.24) (04s) control rod position mm (in) em ‘About 13.141 125 tae sub spring set 75 °0* soo12 Giant, 1340, 52.76) boar ee 7 ere OI gs 7.944:0.294 (79.4429, 10:90, 31.001.18) Strges0 196 (61.88+1.96 | ‘A: 12005 (0.04:0.00201 $590:20, 20.70.79) 451130294 45,11:294, 6030, 8.112118) 3.236:0.196 (9236:1.98, i 330:20, 12:99:0.79) 2.648:0.248 (26.482.8, A: Torave ° aT weno 7579) coast as sora, 1020s 29", eerie onty e rca ec nt 0 17 men 07 i) al cya pi SERIES ST ner 390:20 mts 1290:07 poor 2279 2000010 mere o m1 an 40.24) co "83) {contro od position mm (in) ‘et contol rack limit 017 men (067 in)INJECTION PUMP ASSEMBLY (Diesel Kiki-Bosch it Pump No, 101439.9421, Preumatic F 18.0070 About 12.485 (12858, 11270, 50.00) ttt soning st 75°23 a (0.298 12972 7:355:0206 (73 5512.98, | 750:90 29.53:4.18) 4.90a20.196 (49.0821 96 00:20, 1969:0 78) 451120206 (45.112294, 60:30, 18.1121 1), A: 120.05 (0.04:0.0020) 2154826 245 (26 88:2.45 = 27025, 1083:098). epaive pressure “0.68920400 (8.8324.90, LIK, 4: Terave comet eovet Ps ber, 90:60, 3.54197) mma, naa) / ° spa tS 106 Tia The 1020) 750 otro 43710457) (020° Control rod position mm (in) ——® Sot control rock limit to 13.7 2 mm aaa st imi t0 13.72 mm (0.539 9g ind Mechanica [Below 3 me (0.11 imp 02/,000 avout 2.240 ‘Apply 3 negative presure 3 Pum seed rom ° ait 708 "a4 (02) warn) (0.121904) ‘Control rod sition mm (in) am ° ° Set control rack mit to 13.7_© 5 rom (0.5392 apg in Pump Nos. 10141-9130, 101481.9170 (doves About 10.984 © te sub spring et 8.5 “2 mam (0.335 0"? in (109.84, 1,120, 44.09) * ° 6.57120 .294 (65.7122.94,] = ey Font tet oF ‘ores tseo10%) ns 0m103 901-0008 taraio 294 18601204, laos aac Rereracens teri etn (02156, Sano Soe reese ime i . Cr az (0.224) =) 40.481) tox "207 Control rod position mm (in) ——om st control rack limit to 14.7 ©, mm — cat art 1072 ro 2, wdINJECTION PUMP ASSEMBLY (Diesel Ki Mochanies! About 2,00 — eetow 3 em? (0,18 eu in1,000 st 2,300:30 ‘Apply P3 negative prassure ' 2.160110 3 Pump speed som 0 eao0 7.5 Ta 31012) (0295) (oaay Control rod postion mm (in) —m= og s ‘Ser control rack fimit to 14.7 4mm (0578_9 o40 in) Pump No, 101631 9862 10.012 4) he eget 872 ft 7 12,16120.302 (121 612392, 1240240, 48.261,87) ‘8434:0 204 (64.4:294, (60:30, 33.86¢1.18). 5.689:0.196 (56.88:1.96, 80:20, 72.8520.79) P9 | Negative pressure Pa br. rma, ogee 7a7 worn *'0 oa soo, (oar 12012, Control rod postion mm (in) ——ee Mechanical show 3 em? (0.18 eu in) 1000 fen eee zon " aS control ro position mm (in) ——ee FF-38INJECTION PUMP ASSEMBLY (Di Pump Not. 101441.9120, 10441-9160 Preumatie ‘Anout 10.996 (109.84, 1,120, 44.08) 6.86510.204 (68.65:294, 1700:30,27-56:1.18) 4,70720.196 (47.0721. 1480220, 18.90:0.79), 40.012,,, 7 ° ta srng et 88°23 mn 0.248 Po A: 08:01 (0.02420.004), 1.78510 298 (17:65:24 Negative preture 180290, 7091.18) ka (mbar, (0.98120.196 (9.81:1.96, A: Torque control rave mag, ing) 100220,3.8430.79) ° 0s nT wo2 84 0 (ost) so.012, (o:346 *0.072, Control rod positon mm (in) —e ° o ‘Set control rack mit to 14.7 9 5 mm (0.5799 94 in) ‘Mechanics! ‘About 2,600 | Below 3 em* (0.18 eu in)/1,000 st 2.280130 ‘Apply P3 negative pressure 2.100510 eo Pump speed ep 0 Blow 75 17 34012) (0307) (oe {contro rod position mm (in) we ° -oor2i") ° ‘Set control rack limi to mm tit 10 147.9 5 mm 0.579 TIMER ADVANCE Pump Nos. 101431-9710, 10143-9880, 101431.9900, 101431-9910, 101431-9880, 101433.9060, 101433.9070 Pump seed wm [Below 500 | 500 50 700 900] 1100 | 1300 | 1.500 Degeetorandeot gages | suo | eeowos |eriowo7 | 1:05 | 2:05 | sss | sss | 5108 ‘Pump Nos. 101433.6230, 101433.9260 Pump speed rom__|_ Below £00 500 700 800 1,200 1900 Degree torenglectiead degree | Seno | Beiowos | Betowos | 06205 2205 5105INJECTION PUMP ASSEMBLY (Diesel Pump Nos. 101631-9600, 10161-9660 FF-a0 Pump speed om 500 550 1.100) 1,500 1,900 ‘Deoree forengeofieed dmwee | Beiow0s | Belowo7 | 17:05 | 36:05 6205 ‘Pump Nos. 101691-9551, 101631-0862, 101631-9571 Pump speed ‘om [Below 500 500 550 1,100 1,500 1,900 ‘Degree for ang oftead depres | Start Beiowo7? | 22:05 | 44105 75208 Pump Nos. 101441-9040, 101441 9060, 1014419120, 101441-9160 Pume spew | so9 | a00 | 1,200 | 1.800 | 2,000 ro Deore for angle of| Below ; i iow logsos | 205 | 5:05 eoree Pump Nos. 191431-9430, 101431-9590, 101431-8770 Pump speed om '500*50) 700 ‘200 1,100 11300 1.500 ‘Degree for angle of ead degree | Sure 105 2008 3:05 #08: 5:05 ‘Pump Nos. 1014339370, 101433-9401, 101493-9421 Pump speed om 500 700 1800 1.200 1.800 Desree for angleoftead deyea | Geiow0s | Bsiowos | 06:08 205 05 Pump No, 101433 9431 Pump speed tom 500 ‘900 1,200) 1.500 ‘Degree for angle oflead degree | Belowos | 18:05 33:03, 05 Pump Nor. 101441-9130, 1014419170 Pump speed tom 500 1.200 2,160 Degree for angle oftead _dewree | Below 05 2:05 708TIGHTENING TORQUE INJECTION PUMP ASSEMBLY (Diesel Kil [ee Te aeny Vasco a 0 ; ‘engine front plate = = —_ Daverywee alte | za-34 | aocas | 22.8 ame om [sere | am Teper atwniavett| 529 | 28-20 | 10-22 9 Tiymroundun | 9-80 | 80-60 | 96-48 Tier ind mt se-00 | 00-70 | as-s1 ime weir? | 10-18 | 72-100 terns = Newaiere | 79.06 | 80-100 | 50-72 — incon oie | sa-00 | co-70 | 0-81 Inperionwoetire | ay.24 | a0-a8 | 22-20 Omron es ee Sournioent | 20-40 | 40-80 | 70-00 Fonte cat bt wm | 1820] new ‘cal omer wos | a6.08 | one EF-41 ‘Bosch in-line type)INJECTION PUMP ASSEMBLY (Diese! Kiki-Bosch inline type) SPECIAL SERVICE TOOLS ‘Tool number ‘Tool name DKOS794002 Universal vise a 'sT17080000 Timer wrench (DKS7916432) ee A DK57926512 Extractor DKS7931612 Tappet clamp —_ 'DKS7920032 Delivery valve extractor DKS7911010 ‘Tappet wrench DK0S790502 @ DKS7916432, Special wrench fg 0Ks7952020 | Timer spring support .@ DKS7926581 ‘Timer extractor DK57924162 | Base assembly @ DKS7924190 | Bushing DK57924180 | Bushing guide “© DKS7924170 | Bushing guide @ DK57924161 | Base EF-42INJECTION PUMP ASSEMBLY (Diesel Kiki-Bosch in-line type) reise. nes pK57931210 a a aS SeaaTiaeen aan D Tapes amet — = es a DKS7915422 Special wrench 2 ED resin ears 5 KV11257802 Nozzle holder es ee es A Pe OOS KV11257805 Injection tube c EF-43INJECTION PUMP ASSEMBLY (Diesel Kiki-Bosch VE-type) Tool number Tool name : pul 'ST19530000 Injection pump timer puller KV11205781 Securing stand aL 7 KV11205782 Tappet lift gauge —a d= = KV11205784 Timer coupling INJECTION PUMP ASSEMBLY (DIESEL KIKI-Bosch VE-type) connect overflow hose, fuel inlet hose and fuel return hose DESCRIPTION L._ Disassembly and assembly of this, VE-pump should be done only in service shops authorized by NISSAN/ DATSUN or by the pump manufae- turer. 2. Before removing fuel injection pump from vehicle, check closely to make sure that it is apparently mal- xetioning, XKefer to Trouble-shooting in MA sec- tion. Y /~ serooen| ) IS pur INJECTION PUMP REMOVAL 1, Remove injection tube IN: Cover the injection nozzle assembly 1 ‘with a plug to block the entry of dirt. 3. Remove accelerator wire and dis- ae EF-44INJECTION PUMP ASSEMBLY (Diesel Kiki-Bosch VE-type) 5. Loosen injection pump drive gear faut and remove drive gear by using paler. ‘nuts and bolts, injection tubes. serorza Disconnect injection tube from ump once itis removed. INSTALLATION 1, Align front cover and crank pulley ‘mark for setting No. 1 piston at T.D.C. KV11229082 \ et SEror6a| 2. Injection pump (1) Temporarily set injection pump so that the flange of pump is aligned with aligning mark on front cover (@) Mesh injection pump drive gear with idler gear at “Y" mark and then align gear to key way of injection pump camshaft while turning. erank pulley. Coat key with grease to prevent it from falling into front cover, and lay {rag on front cover. (3) Tighten drive gear fixing nut D : Drive gear fixing nut 59-69N-m (6-7kg-m, 43-61 feb) (@) Install drive gear cover with new gasket. ADJUSTMENT 1. Loosen the three injection pump mounting nuts and mount bracket bolt. 2. Remove plug bolt from distribu- ‘tor head and install Tool FF-45 3. Plunger lift measurement and ad- justment. (Q) Turn crankshaft counterclockwise 20 to 25 degrees from No. 1 Piston at Top Dead Center. (2) Find dial gauge’s needle rest posi- tion at step (1) set position, then set the gauge to zero, (3) Turn crankshaft clockwise until No. | piston is set at Top Dead Center. (4) Read dial gauge indication, ‘so22: 1.0340.02 mm (0,0406+0.0008 in) 0,950.02 mm (0.0374+0.0008 in) {Only for pump No. 104749.4040 and 14749-4080] sz: 0,940.02 mm (0.03700,0008 in) 8025: 0.890.02 mm (0.0350+0.0008 in) (8) If dial gauge indication is not within the above range, tum pump body until it falls within standard range. 4. If indication is smaller than the specified value, turn pump body ‘counterclockwise. ». If indication is larger than the speci- fied value, turn pump body clock- wise, 4. Tighten injection pump securely. ® = Injection pump fixing bolt 20-25 Nem (20-25 kom, 14-18 feb) Injection pump to mounting bracket 16-22 Nm (1.62.2 kom, 12-16 fb)INJECTION PUMP ASSEMBLY (Diesel Kiki-Bosch VE-type) 5. Disconnect dial gauge and reinstall plug bolt with new washer in its pos tion. 6. Connect injection tubes. seresa] DRAIN WATER Drain water from fuel filter in [Use two wrenches for removing and accordance wide suelniamance sthed- installing tubes. tle. Also do this when warning light Flare nut ‘comes on. 29-34Nm 1. Disconnect fuel filter sensor har- (30-3.5kom, nes. 22-25 ftlb) > 2. Loosen fuel filter sensor and drain water a. Be sure to place @ container beneath fuel filter. ', Pumping priming pump will quick en water drainage. 7. Bleed air from fuel system. 3. When fuel overflows, retighten ‘and connect fuel filter sensor. CHECKING PRIMING PUMP 1, Disconnect fuel return hose. BLEEDING FUEL SYSTEM eae aioe Nee hose end. Air should be bled out of fuel system when injection pump is re- moved or fuel system is repaired. 2. Prime priming pump to make sure that fuel overflows at hose end. If not, replace priming pump. 1, Loosen vent screw and priming, FF-46 Make sure that fuel overflows at vent screw hole. 2. Tighten vent screw. 3. Loosen injection pump bleeder serew/or disconnect return hose and priming. Protect pump and engine mounts from ‘tuo splash with rags. 4, Make sure that fuel overflows at bleeder serew/tube end, then tighten it/connect hose. If engine will not start, loosen injec: tion tubes at nozzle side and crank en: ‘gine until fuel overflows from injec: tion tube. Tighten injection tube flare nus. IDLE AND MAXIMUM SPEED ADJUSTMENTS, Refer to Section MA for these adjust: