FUEL SYSTEM F1

FUEL SYSTEM
PREPARATION
SST

~
49 SEQl 157 For
removal of
Extractor injection pump

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9TGOF1·026

FUEL TANK
Removal I Inspection I Installation
1. Remove in the order shown in the figure.
2. Inspect all parts and repair or replace as necessary.
3. Install in the reverse order of removal.

Warning
• Keep sparks, cigarettes, and open flames away from the fuel tank.

Note
• Drain the fuel before removing the fuel tank.

4
Nom (m-kg, 'loIb)
9TGOF1--027

1. Connector 4. Fuel tank strap

2. Fuel hose 5. Fuel tank
3. Evaporative hose Check for contamination, cracks and other
Be sure the air flows through the hose damage
each side

F1-13
F1 FUEL SYSTEM
INJECTION PUMP

Note
• Special tools and testers are required for service of the injection pump. The pump should be
serviced only by an authorized Diesel Kiki distributor.

Removal/Installation

Warning
• Keep sparks cigarettes, and open flames away from the injection pump.

1. Remove the· negative battery cable.

2. Remove in the order shown in the figure. referring to Removal Note.
3. Install in the reverse order of removal. referring to Installation Note.
4. Adjust the injection timing. (Refer to page F1-9.)
5. Bleed air from the fuel system. (Refer to page F1-17.)

(2.2-3.1. 1s-:.22)

Nom (m-kg, tt...)

9TGOF1.()28

1. Fan and upper cooling fan shroud 6. Pump cover

2. Air hose 7. Locknut
3. Injection pipe 8. Washer
4. Accelerator pipe, Idle-up cable 9. Injection pump
5. Harness

F1-14
 FUEL SYSTEM F1
Removal Note
1. Before removal the injection pump, turn the flywheel through
the clutch cover timing hole until the key is at the top posi-
tion. Use a mirror to see key.

2. Attach the SST. (Use the side marked M.)

3. Turn the SST bolt to push the pump free of the drive gear.

Caution
• Do not drop the key into the gear case.

Installation Note
Before installing the key into the driveshaft of the injection
pump, lightly tab the key groove of the shaft with a hammer
to assure that the key is tightly held in the key groove.

9TGOF'031

F1-15
F1 FUEL SYSTEM
SEDIMENTOR

,.,• Draining water

Note
• Drain water when the sedimentor warning light is
illuminated or when the float ring has risen near the
float level line.
SEDIMENT
I
I
FLOAT LEVEL
LINE I I

1. Loosen the drain plug.

2. Loosen the air bleeder plug.
3. After all of the water has been drained, install the drain plug.
4. Pump the priming pump at the fuel filter until clear (no air
bubbles) fuel is expelled from the air bleeder plug. Tighten
the bleeder plug.

Inspection
1 . Visually check the sedimentor for damage and fuel leak-
age. Repair or replace, if necessary.
2. Check the position of the float ring. If the ring is near the
float level line, drain the water. .

SEDIMENTOR SENSOR (DETECTOR)

·1 nspection
1. Remove the sedimentor sensor from sedimentor.
2. Check continuity of the detector.

Float Continuity
Up Yes
CONTINUE
Down No

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9TGOF1·035
Replacement

Warning
• Keep sparks, cigarettes, and open flames away from
the sedimentor.

1. Disconnect the terminals.

2. Remove the fuel hoses.
3. Remove the sedimentor.
4. Install in the reverse order of removal.

9TGOF1-036
F1-16
 FUEL SYSTEM F1
FUEL FILTER
PRIMING PUMP Air Bleeding

Warning
• Keep sparks, cigarettes, and open flames away from
the fuel filter.

1. Remove the air bleeder plug.

2. Pump the priming pump until clear (no air bubbles) fuel flows
from the bleeder plug hole.
3. Install the air bleeder plug.

4. Loosen the overflow pipe connector of the injection pump.

5. Pump the priming pump until fuel flows from the pipe.
6. Tighten the overflow pipe connector.

Tightening torque:
20-29 N·m (2.0-3.0 m-kg, 14-22 ft-Ib)

7. Start the engine and run it at idle until it runs smoothly. Stop
the engine.

8. Loosen the aU flare nuts of the injection pipes of injection

nozzle side.
9. Confirm fuel injection from the injection pipes while cranking.
10. Tighten the nuts.

Tightening torque:
20-25 N·m (2.0-2.5 m-kg, 14-18 ft-Ib)

Inspection of priming pump

Warning
AIR BLEED • Keep sparks, cigarettes, and open flames away from
the fuel filter.

1. Remove the air bleeder plug and verify that fuel flows from
the bleeder plug hole while pumQ1ng the priming pump. If
it does not, continue with step 2.

9TGOF1-()40
2. Remove the fuel hose from the inlet side of the filter.
3. Place a finger over the inlet part and verify that vacuum is
felt when the pump in operated.
4. Replace the priming pump if not as specified.

"
:
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"

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----
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~"""""'~-~. \ \

.. ~, \.~
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I

9TGOF1·041
F1-17
F1 FUEL SYSTEM
Replacement

Warning
• Keep sparks, cigarettes, and open flames away from the priming pump.

1. Remove in the order shown in the figure.

2. Install in the reverse order of removal.
3. Bleed air from the fuel system. (Refer to page F1-17.)
4. Run the engine and verify that there are no fuel leaks.

37-52 (3.8-5.3, 27-38)

CD

N-m (m«g, ft..Jb)

9TGOFH)42
1. Filter element 2. Fuel filter body
Removal Note ........................... page F1-18
Installation Note ........................ page F1-18

Removal Note
1. Remove the filter element with an oil filter wrench.

9TGOF1-()43
Installation Note
1. Apply fuel to the O-ring.
2. Install the filter element and tighten by hand, then tighten
with an oil filter wrench an additional 1/3-turn.

9TGOF1.()44
F1-18
 FUEL SYSTEM F1
INJECTION NOZZLE
Removal

Warning
• Keep sparks, cigarettes, and open flames away from the fuel area.

1 . Remove the negative battery cable.

2. Remove in the order shown in the figure.

Nom (m-kg. ft-lb)

9TGOF1 -C>4S

1. Injection pipe 3. Injection nozzle

2. Return pipe

Inspection

Warning
• Do not allow your hands or any other part of the body to come into the direct path of the spray
when using the nozzle tester because the spray has enough force to break the skin and ·possi-
bly cause blood poisoning.

Caution
• The nozzle tester should be set up in a clean work place.
9TGOF1·046

Injection starting pressure

1. Connect the nozzle to a nozzle tester.
2. Pump the nozzle tester handle and note the pressure when
injection is started.

Injection starting pressure:

13,244-13,734 kPa
(135-140 kg/cm2 , 1,920-1,991 psi)

F1-19
F1 FUEL SYSTEM
3. If not within the specified pressure, adjust the starting pres-
sure by adding or removing shims.
ADJUSTING SHIM
Note
• Shims are available in thicknesses of 0.5mm (0.0197
in) to 1.45mm (0.0571 in) in 0.04mm (0.0016 in)
increments. Adding 0.04mm (0.0016 in) shim thick-
ness increases injection starting pressure approx.
471 kPa (4.8 kg/cm 2 , 68 psi).

9TGOF1·048
Leakage of injector
1. Connect the nozzle to a nozzle tester.
2. Apply pressure 1,962 kPa (20 kg/cm2, 284 psi) lower than
the specified injection pressure, and verify that no fuel leaks
from the injection nozzle.
3. If fuel leaks, disassemble, clean and recheck the nozzle,
or replace it

CORRECT WRONG

9TGQF1·049
Atomizing condition
1. Connect the nozzle on the nozzle tester.
2. Air bleed by operating the nozzle tester handle several times.
3. Keeping the pressure gauge of the nozzle tester in the non-
functioning condition, quickly lower the handle (lower the
handle as quickly as possible so that a pulsating whistling
sound can be heard). Repeat this operation several times
I I. • \
and check the atomizing condition.
4. Verify that the fuel is atomized uniformly and properly.
CORRECT WRONG- WRONG 5. Verify that the injection angle and direction are normal.
6. If the atomizing condition is incorrect, it is necessary to dis-
9TGOF1·0SO assemble, wash and recheck the nozzle, or to replace it.

Disassembly
1. Clamp the nozzle in a vise as shown in the figure.

9TGOF1·OS1
2. Disassemble as shown in the figure.
(DRetaining nut
@Nozzle body
@Distance piece
@Pressure pin
@Pressure spring
@Shim
0Nozzle holder

9TGOF1·052
F1-20
 FUEL SYSTEM F1
Checking Injection Nozzle
1. Verify that the seat of the pressure pin and other parts are
free of damage.

2. Verify that the nozzle body is not damaged.

Hold the nozzle body upright and insert the needle valve
approximately two-thirds of the way into the body. Verify
that the needle valve drops into the body under its own
weight when released.

9TGDF1·D54
Assembly
1 . Assemble in the reverse order of disassembly.

Jt Tightening torque:
78-98 N·m (8.0-10.0 m-kg, 58-72 ft-Ib)

iq --
I
-i--

1""'\
.'
L----
.r- 2. Retest the nozzle after assembly.

9TGDF1·055
Installation

Caution
• Do not reuse the copper washers. .
• Tighten the nozzle into the cylinder head to the
specified torque.

1 . Install in the reverse order of removal.

Tightening torque:
59-69 N-m (6.0-7.0 m-kg, 43-51 ft-Ib)

2. Run the engine and check for fuel leakage.

9TGDF1·D56

F1-21
F1 FUEL .SYSTEM
ACCELERATOR PEDAL, ACCELERATOR CABLE
Inspection I Adjustment
1. Verify that the control lever of injection pump is in the fuUy-
open position when the accelerator pedal is fully depressed.
2. Loosen nut A and adjust the stop bolt if necessary.

Tightening torque:
6.9-9.8 N-m (0.7-1.0 m-kg, 5.1-7.2 ft-Ib)

3. Check the free play of the accelerator cable.

Free play: 1.0-3.0mm (0.039-0.12 in)

4. Adjust nuts B if necessary.

Tightening torque:
9.8-15 N-m (1.0-1.5 m-kg, 7.2-11 ft-Ib)

9TGOF1-058

Removal I Installation
1. Remove in the order shown in the figure.
2. Install in the reverse order of removal.

2.5-4.9 N-m
(25-50 cm-kg.

22-43~

!~
6.9-9.8 No/II
(70-100 cm-kg. 9.8-14.9 N-m
61-87 in-Ib) (100-150 cm-kg.
87-:130 in-Ib)

9TGOF1-059
1. Accelerator cable 3. Bracket
2. Accelerator pedal

F1-22
FUEL CUT CONTROL SYSTEM F1
FUEL CUT CONTROL SYSTEM
SYSTEM OPERATION
1 . Verify that the engine stops when the fuel cut solenoid valve
connector is disconnected.

FUEL CUT SOLENOID VALVE

Inspection
1. Verify that the fuel cut solenoid valve clicks when the en-
gine switch is turned ON and OFF.
2. If it does not, disconnect the fuel cut solenoid valve and
check the voltage to the valve.

Engine switch Voltage

ON 12V
OFF OV
3. If as specified, replace the fuel cut solenoid valve.
9TGOF1.oel

Replacement
1. Disconnect the fuel cut solenoid valve connector.
2. Remove the fuel cut solenoid valve from the injection pump.
3. Install in the reverse order of removal.

Tightening torque:
39-44 N-rn (4.0-4.5 m-kg, 29-33 ft-Ib)

9TGOF1·062

F1-23