FUEL SYSTEM

1. Description

Fuel filter

Fuel inlet Leak off pipe

Injection nozzle

Return pipe

Fuel
outlet

Injection pump

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2. Fuel System Bleeding

Fuel filter
Priming button
(1) Loosen air vent plug on the fuel filter (by turning it 1.5
turns).
(2) Pump the priming button on the fuel feed pump.
(3) Tighten the air vent plug when the fuel flows free of
bubbles.

Air vent plug

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3. Disassembly

(1) Disconnecting fuel pipes

Injection pipe
Remove the pipe clamps from the injection pipes. Leak-off pipe
Disconnect the injection pipes at the injection pump and at
Lock nut
the injection nozzles. Disconnect the leak-off pipes from
the nozzles by loosening the lock nuts.
Return pipe
Fuel hose
CAUTION
Clamp
Put protection caps on the pump and nozzles to
keep dirt and foreign material out of the fuel
system.

Disconnecting fuel pipes

(2) Removing fuel injection nozzles

Using a box wrench, remove the fuel injection nozzles with
gaskets from the engine.

NOTE
Remove the nozzle gaskets from the cylinder head, if
any, with a wire or a screwdriver and discard them.

Removing fuel injection nozzles

(3) Removing fuel injection pump

(a) Check the alignment of the mark on the fuel injection
pump with the mark on the flange plate.

Removing fuel injection pump (1)

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(b) Remove the front end cover from the engine. Idler gear
(c) Put marks on the fuel injection pump drive gear and
idler gear.
(d) Unscrew the bolts that hold the fuel injection pump

33
3
flange to the front end plate and remove the pump and
flange from the end plate.

NOTE
(1) Do not attempt to turn the engine after removing Fuel injection
pump drive gear
the injection pump from the engine.
(2) To remove the fuel injection pump drive gear,
loosen its nut with the pump on the engine. Removing fuel injection pump (2)

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4. Fuel Filter (Paper-Element Cartridge Type)

Disassembly and Inspection

Clacks, damaged
threads.
3

Air vent plug

Clogged, cracked.
Replace every 500
service hours.

Disassembly sequence
1 Level sensor assembly 3 Bracket
2 Element assembly

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5. Fuel Injection Nozzles

5.1 Disassembly

Check for wear. 7

Check for defect. 6

5
4

Check for wear. 3

2
Check for carbon on tip
or in orifice.
1

Disassembly sequence
1 Retaining nut 5 Spring
2 Nozzle tip assembly 6 Washer
3 Piece 7 Nozzle body
4 Pin

5.2 Testing
(1) Injection pressure (valve opening pressure)
(a) Install the injection nozzle on the tester. Slowly
operate the tester handle full strokes to bleed (remove)
air from the pipe and nozzle.
(b) Make a slow increase in pressure by operating the
tester handle at a speed of more than one stroke per
second while observing the pressure gage.
Testing fuel injection nozzle
(c) The pressure gage reading will slowly increase and,
when the nozzle starts discharging fuel, it will go down
fast. Take the gage reading right then as the injection CAUTION
pressure When testing the injection nozzle, keep its
Unit: MPa (kgf/cm ) [psi] 2 tip pointed away from the operator. Fuel
Item Assembly Standard from the orifices in the tip of the nozzle is
+ 0.98 + 10 + 142
under high pressure and can cause injury
Injection pressure 11.77 0 (120 0 ) [1707 0 ] to the operator.

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(d) If the injection pressure is not correct, make an

adjustment of the nozzle by adding or removing the
shims inside the nozzle holder.

NOTE
With an increment or decrement of 0.1 mm (0.0039
in.) in washer thickness, the injection valve opening
pressure varies by 0.98 MPa (10 kgf/cm2) [142 psi].
Variation in adjusting washer thickness:
1.25 to 1.7 mm (0.0492 to 0.0669 in.) [at steps of 0.05
Removing nozzle tip
mm (0.0020 in.)]

(2) Spray pattern

(a) Operate the tester handle at a speed of one stroke per
second and look at the spray pattern (shape of
discharge) when fluid begins to flow through the fuel
injection nozzle. The discharge must be 0°. Any
change is an indication of a bad nozzle.
Good nozzles Bad nozzles
(reusable) (recondition or replace
if necessary)

Possible spray pattern

(b) If the nozzle is bad, loosen the retaining nut and

remove the tip from the nozzle. Wash the tip — needle
valve and body — in clean diesel fuel. After washing,
put the needle valve in the body in clean diesel fuel.

CAUTION
(1) Be careful not to cause damage to the tip
when removing it from the nozzle body.
Needle valve
(c) After cleaning the nozzle tip, install it to the nozzle Body
body and tighten the retaining nut to the specified
Washing nozzle tip
torque.

37 ± 2.5 N·m
Tightening torque (3.77 ± 0.25 kgf·m)
[27 ± 1.8 lbf·ft]

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(d) If the discharge pattern (nozzle) is still bad after the

nozzle tip has been washed, replace the tip.

NOTE
(1) Do not touch the sliding surface of the needle
valve.
(2) When installing a new nozzle tip, remove resin
film from the tip and slide the needle valve in the
body in clean diesel fuel to wash off inhibitor
completely.

5.3 Reassembly

5 Retaining nut
Tightening torque:
37 ± 2.5 N·m (3.77 ± 0.25 kgf·m)
[27 ± 1.8 lbf·ft]
4

3 Tightening torque for fuel

injection nozzle:
2 59 ± 10 N·m (6.0 ± 1 kgf·m)
1 [44 ± 7 lbf·ft]

Reassembly sequence
← ← ← ← ← ←
7 6 5 4 3 2 1

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