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FUEL SYSTEM

1. Description ......................................................................................... 11 1
2. Fuel Filter (Paper-Element Cartridge Type) ............................... 11 2
Disassembly and Inspection .................................................................. 11 2
3. Injection Nozzles................................................................................ 11 3
3.1 Disassembly .................................................................................... 11 3
3.2 Inspection........................................................................................ 11 4
3.3 Reassembly .................................................................................... 11 6

11
FUEL SYSTEM

1. Description

Air vent plug Fuel injection nozzle

Fuel filter

Air vent plug

Fuel injection pump Return pipe

Fuel inlet

Fuel feed pump

11-1
FUEL SYSTEM

2. Fuel Filter (Paper-Element Cartridge Type)

Disassembly and Inspection

Air vent plug

2 Check for cracking


or stripped thread.

When installing a new


filter, apply engine oil
to packing.

1
Check for clogging or
cracking. Replace
every 500 hours.

Disassembly sequence
1 Element assembly 2 Bracket

11-2
FUEL SYSTEM

3. Injection Nozzles

3.1 Disassembly

Replace: Gasket

Wear
7

Fatigue or squareness 6

4
Wear or damage
3

2
Carbon deposit or
clogging of orifice
1

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

11-3
FUEL SYSTEM

3.2 Inspection
(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 gauge.
(c) The pressure gauge reading will slowly increase
and, when the nozzle starts discharging fuel, it will
go down fast. Take the gauge reading right then as
the injection pressure. Testing fuel injection nozzle
Unit: MPa (kgf/cm ) [psi]
2

Nominal Assembly
Item
Value Standard
11.77 11.77 to 12.75
Injection pressure (120) (120 to 130)
[1707] [1707 to 1849]

WARNING
When testing the injection nozzle, keep its tip
pointed away from the operator. Fuel from the orifice
in the tip of the nozzle is under high pressure and
could cause injury to the operator.

(d) To adjust the injection pressure, increase or decrease


the amount of shims fitted to the nozzle holder.
Nozzle tip orifice
NOTE
0.1 mm (0.004 in.) thickness of shims will change the
injection pressure approximately 1 MPa (10 kgf/cm2)
[142 psi]. The shims are available in 10 different
thicknesses from 1.25 mm (0.049 in.) to 1.7 mm
(0.067 in.) in increments of 0.05 mm (0.002 in.) for
the swirl chamber type engines.
Removing nozzle tip

11-4
FUEL SYSTEM

(2) Spray pattern


(a) Operate the handle of the tester at a speed of one
stroke per second and look at the orifice discharge
pattern (shape of discharge) when fluid begins to
flow through the injection nozzle. The discharge
must be straight. It must be finely and uniformly
atomized. Any change is an indication of a bad Good Dribbling Feathering
nozzle. Diffused Deflected

Spray pattern

(b) If the nozzle is bad, remove the tip from the nozzle
and wash needle valve and body in clean washing
solution.
(c) If the nozzle is still bad after the tip has been
washed, replace the tip.

NOTE
When installing the new tip, remove synthetic resin
film from the tip and slide the needle valve in the body Needle
valve
in clean diesel fuel to wash off inhibitor completely.
Body

Washing nozzle tip

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FUEL SYSTEM

3.3 Reassembly

5 Retaining nut
Tightening torque to body:
34.3 to 39.2 Nm
(3.5 to 4.0 kgfm)
4 [25.3 to 28.9 lbfft]

3 Tightening torque to engine:


49.0 to 68.6 Nm
2 (5.0 to 7.0 kgfm)
[36.2 to 50.6 lbfft]
1

Reassembly sequence

7 6 5 4 3 2 1

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