Inline injection pump removal, installation and timing

Required materials:
 Engine whose condition is to be determined
 Inspection pipe
 Appropriate hand tools
 Shop manual

Notice
For all checks,tests and adjustment excueted always manufacturer’s recommendations
and specification should be taken in to account.
1. inline injection pump removal/installation
although the removal/installation procedures are similar for all injection pumps.
Individual service manualshould be always be reffered to before one remove the
pump.

Notice:
Clean the surrounding area of the injection pump and fuel lines thoroughly before
starting the removal procedure and close or cap all opening to prevent dirt from
entering.
Removal procedure
 turn the crankshaft to bring No.1 piston to TDC on compression stroke, so that
the timing marks are aligned ‘O’ mark on the crankshaft pulley should match
with the pointer to the engine casing.
 Remove or disconnect engine control cable and/or shut off lever and all
connections from accessories attached to the injection pump where provided.
 Disconnect the inlet fuel connection the fuel return line conection,if used, by
using the proper spanner and collect the out running fuel with a container.
 Disconnect the high pressure injection lines from deliuvery valve holder or
injector, whichever is easier, by using the proper and correct sized spanner.
 Remove the injection pump rear support and flange plate mounting bolts or
nuts.
 Finally, remove the injection pump by withdrawing rearwards.

Checking and adjusting fuel injection timing

Checking procedure
 Remove injection pump, delivery valve, spring and stopper from No.1 pumping
element of the injection pump, next reinstall delivery valve holder again.
Note; put the valve components in clean diesel fuel inoder vto keep them clean and
out of dust.
 Fit an injrection pipe to No.1 pumping element delivery valve holder, so that out
coming fuel is clearly observed.
 Rotate the crankshaft in normal direction of engine rotation until No1 cylinder
close to 300 BTDC.
 WHILE OPERATING THE PRIMING PUMP ( fuel will run out from the
inspection pipe) slowely rotate the crankshaft in its direction of normal rotation.
  Make sure that the stop lever, positioned on top of the governor, is not in
its stop position.
 Use a container to collect the fuel coming out from the inspection pipe.
 Rotate the engine until fuel has almost stopped from running out of
the inspection pipe.
 After the fuel has completely stopped from running out stop
rotating the engine. now check if injection timing marks placed on
crankshaft pulley and engine casing are in alignment (180 BTDC)
 If this is not a case, the injection pump timing has to be corrected
(adjusted).

Injection timing adjustment procedure

 Lossen the injection pump fastening nuts slightly.
 Adjust the injection tinming according to manufacturer’s specification.
 If injection timing is retarded, slowely move pump towards the crankcase
 If injection timing is advanced, slowely move pump away from the
crankcase.
Note:
By moving the pump one division of the adjusting amount mark this will advance or
retard the injection timing for 60 of crankshaft rotation.
 Tighten the injection pump and recheck the injection timing adjustment.
 If the injection timing adjustment is correct. Install the delivery valve
components and tighten the delivery valve holder to the specified torque.
 Fit the injection pipe to the delivery valve holder ande test run the engine.
Note:
Position of alignment marks injection timing on the diesel engine and injection
timing adjustment are exact. The exact starting of fuel delivery is attached, if one
fuel drop each second leaves the injection pipe.

Fig
Installation procedure
 Place the piston No.1 cylinder at TDC on compression “O” marks on
crankshaft pulley should match with the pointer attached to engine casing.
Note:
Rotate crankshaft in its direction of normal rotation only.
 Line up the notch of the injection pump gear with the alignment marks on the
pump flange plate.
 Now, first insert the guide bar of the flange plate in to the guide hole of the
front plate.
Next, carefully push in the injection pump up to the point before it meshes with
the idle gear.
 Check to ensure that the notch on the injection pump gear aligns with the
alignment mark on the flange plate.
 Install the flange plate to the timing gear case and fit the rear stay( support).
  Don’t forget to bleed the fuel system after the injection pump has
been installed.
 Check and/or adjust the fuel injection start timing if necessary.

Service of Fuel injection nozzle and holder

Materials:
 Injector test machine
 Various injector (pintle type and mulit hole type)
 Shop manual
 Appropriate hand tools
Removing injector
 Generally the removing procedure is the same as ,though the position of the
injector and its hold-down device may differ from engine to engine.
 First clean the area around the injectors and glow plugs thoroughly and dry it with
compresses air.
 Remove the high pressure line and leak off fuel lines from the injector inlet and
leak off connection.
 Use two spanners in order to prevent damage to the fitting or twisting of the fuel
lines when loosening the connection.
 After this, immediately close or cap all openings to prevent dirt from entering.
 Remove the injector or its hold-down device first, w/h secures it to the cylinder
head. If provided.
 Cover the nozzle tip to prevent it from damage and the opening in the cylinder
head in order to prevent dirt from entering.

Injector testing
 Before disassembling an injector, an important step in the servicing procedure of
an injector to test it.
 The injector is connected to the pressure line of the injector tester and tightened
after the air is removed.
 The test executed in the following order:
1. opening pressure test
2. leakage test or valve seat test
3. back pressure test
4. spry pattern test