INJECTION PUMP TEST SPECIFICATIONS 096000-0390,1

MANUFACTURER TOYOTA
INJECTION PUMP 096000-039#
ENGINE TYPE L VE4/9F2200RND039
VEHICLE MODEL CROWN ROTATION Clockwise viewed from GOVERNOR TYPE All speed
drive side
RATED VOLTAGE 12V INJECTION ORDER A-B-C-D INJECTION INTERVAL 90° ± 30'
Dimension KF (mm) 5.40 ± 0.10 Dimension MS (mm) 0.65 ± 0.10
Dimension K (mm) 3.30 ± 0.10 Dimension PS (mm) —
1. TEST CONDITIONS
Nozzle 093400-0050 (DN4SD24A) Feed Pressure 19.6 kPa ( 0.2 kgf/cm2)
Nozzle Opening Pressure 11.8 MPa ( 120 kgf/cm2) High Pressure Pipe Ø2 × Ø6 × 840 mm
Test Oil SAE J967 (ISO4113) Fuel Temperature 40 - 45 °C (104 - 113°F)
NOTE : Apply 8 volts DC across the fuel cut solenoid during adjustment.
2. PRE-ADJUSTMENT
Lever Position Pump Speed Boost Pressure Fuel Delivery Max. Spread
in Delivery
(deg) (rpm)
(kPa) (mmHg) (mm3/st) (cc/200st) (mm3) (cc)

Full Load 18 ± 5° 1200 — — 37.5 ± 1.0 7.5 ± 0.2 2.0 0.4

(Full position)
High Speed 2450 — — 14.8 ± 2.8 3.0 ± 0.6 — —
3. ADJUSTMENT OF INTERNAL PRESSURE
Lever Position Pump Speed Boost Pressure Internal Pressure Remarks
(rpm) (kPa) (mmHg) (kPa) (kgf/cm2)

Full 400 — — 245.2 ± 29.4 2.5 ± 0.3 By the regulating valve

2200 — — 686.5 ± 29.4 7.0 ± 0.3

4. OVERFLOW QUANTITY CHECK

Lever Position Pump Speed Boost Pressure Overflow Quantity Remarks
(rpm) (kPa) (mmHg) (L/h) (cc/1000st)
Full 2200 — — 22 - 48 167 - 364
NOTE : The overflow valve belonging to the pump should be used checking.

5. ADJUSTMENT OF TIMER
Lever Position Pump Speed Boost Pressure Piston Travel Remarks
(rpm) (kPa) (mmHg) (mm)

Full 600 — — 0.45 ± 0.35

1200 — — 2.80 ± 0.40

2000 — — 6.00 ± 0.40

2300 — — 6.75 ± 0.40

NOTE : Hysteresis at each pump speed is less than 0.3 mm.

2004.07.12
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6. ADJUSTMENT OF BOOST COMPENSATOR — : Not Applicable

Lever Pump Boost Pressure Fuel Delivery Max. Spread Remarks

Speed in Delivery
Position (rpm) (kPa) (mmHg) (mm /st)
3
(cc/200st) (mm ) (cc)3

— — — — — — — — —

7. ADJUSTMENT OF FUEL DELIVERY

Lever Pump Boost Pressure Fuel Delivery Max. Spread Remarks

Speed in Delivery
Position (rpm) (kPa) (mmHg) (mm3/st) (cc/200st) (mm3) (cc)

Full 1200 — — 37.5 ± 1.0 7.5 ± 0.2 — — By full load setting screw

2450 — — 14.8 ± 2.8 3.0 ± 0.6 — — By max. speed setting screw

2300 — — 30.0 ± 3.0 6.0 ± 0.6 — —

Less than Less than
2600 — — 5.0 1.0 — —

100 — — 52.5 ± 7.5 10.5 ± 1.5 5.0 1.0 By governor sleeve plug

350 — — 40.5 ± 4.0 8.1 ± 0.8 2.5 0.5 End of fuel quantity increase

500 — — 32.5 ± 2.5 6.5 ± 0.5 2.5 0.5

800 — — 37.3 ± 1.8 7.5 ± 0.4 2.5 0.5

1800 — — 41.8 ± 1.3 8.4 ± 0.3 2.5 0.5

2100 — — 39.8 ± 1.3 = A 8.0 ± 0.3 = A 2.5 0.5

8. SETTING OF LOAD SENSING TIMER

Lever Position Pump Speed Boost Pressure Fuel Delivery Remarks
(rpm) (kPa) (mmHg) (mm3/st) (cc/200st)

Start of Load Sensing 2100 — — (A – 7.0) ± 2.0 (A – 1.4) ± 0.4 By governor shaft

End of Pressure Drop 1200 — — 14.0 ± 1.0 2.8 ± 0.2 Check

Repeat Advance Angle — — — — — —

Check Points 1. Change of Piston Travel : 1.40 ± 0.20 mm (Pump speed 1200 rpm)

2. — : — mm

3. Dimension of Governor Shaft : L = 1.50 ± 0.50 mm

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9. SETTING OF ADJUSTING LEVER AT LOW SPEED
Lever Pump Boost Pressure Fuel Delivery Max. Spread Remarks
Position Speed in Delivery
(deg) (rpm) (kPa) (mm /st)
3
(cc/500st) (mm ) (cc)
3

– 19 ± 5° 350 — 9.5 ± 1.5 4.8 ± 0.8 2.0 1.0 Lever setting

(Idle position)
Less than Less than
525 — 1.0 0.5 — —

10. SETTING OF ADJUSTING LEVER AT PARTIAL RANGE — : Not Applicable

Pump Speed Boost Pressure Fuel Delivery Remarks
(rpm) (kPa) (mmHg) (mm3/st) (cc/500st)

— — — — — —

11. CHARACTERISTIC OF A.C.S.D. — : Not Applicable

Lever Pump Speed Boost Pressure Measuring Value Remarks
Position (rpm) (kPa) (mmHg)
— — — — — —

Fuel temperature : 39 - 41°C

12. ADJUSTMENT OF T.C.V. — : Not Applicable
Lever Position Pump Speed Boost Pressure Piston Travel Remarks
(rpm) (kPa) (mmHg) (mm)
— — — — — —

13. SETTING OF DIAPHRAGM FOR HEATER & POWER STEERING — : Not Applicable
Pump Speed Vacuum Pressure Fuel Delivery Remarks
(rpm) (kPa) (mmHg) (mm3/st) (cc/500st)
— — — — — —

14. ADJUSTMENT OF POWER CONTROL — : Not Applicable

Lever Pump Speed Boost Pressure Fuel Delivery Remarks
Position (rpm) (kPa) (mmHg) (mm3/st) (cc/200st)
— — — — — — —
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15. ADJUSTMENT OF THROTTLE POSITION SENSOR — : Not Applicable

Lever Position Pump Speed Boost Pressure Fuel Delivery Sensor Remarks
Output
(rpm) (kPa) (mmHg) (mm3/st) (cc/500st) Voltage (V)

— — — — — — — —

16. FINAL CHECK AFTER ADJUSTMENT

1. Lever position at idle is – 19 ± 5° and 18 ± 5° at full.
2. After adgustment has been completed, delivery quantity must be 0 mm3/st (0 cc/200st) when
voltage at fuel cut solenoid is reduced to zero. (Pump Speed Np = 350 rpm)