Type 1
Fuel Injection Pump and Governor
Illustration 1 | g01024785 |
Right side view Typical example |
(1) Tighten the bushing to the following torque. ... 270 ± 13 N·m (200 ± 10 lb ft)
(2) Pin hole for zero rack (LH)
(3) Hole for timing pin
(4) Pin hole for zero rack (RH)
(5) Fuel Inlet from secondary filter
(6) Tighten the bolts to the following torque. ... 14 ± 4 N·m (10 ± 3 lb ft)
Illustration 2 | g00707963 |
(7) Fuel return to tank (automatic purge)
(8) Fuel bypass valve
(9) Rotary servo assembly
Illustration 3 | g00707967 |
View E-E |
(10) 4N-0605 Spring for servo assembly
- Length under test force ... 22.35 mm (0.880 inch)
- Test force ... 15.70 ± 0.80 N (3.53 ± 0.18 lb)
- Free length after test ... 43.92 mm (1.729 inch)
- Outside diameter ... 13.39 mm (0.527 inch)
- Test force ... 15.70 ± 0.80 N (3.53 ± 0.18 lb)
Illustration 4 | g00707969 |
View F-F |
(11) The inside diameter of servo assembly for the oil pump rotor ... 12.706 ± 0.006 mm (0.5002 ± 0.0002 inch)
(12) The inside diameter of the shaft bearing ... 12.720 ± 0.013 mm (0.5008 ± 0.0005 inch)
(13) Shaft diameter ... 12.682 ± 0.008 mm (0.4993 ± 0.0003 inch)
Note: The shaft must rotate freely after the cover is tightened.
Illustration 5 | g00707971 |
View C-C |
(14) 9Y-6083 Spring (Regulating fuel pressure)
- Length under test force ... 26.24 mm (1.033 inch)
- Test force ... 13.4 ± 0.7 N (3.01 ± 0.15 lb)
- Free length after test ... 43.31 ± 0.91 mm (1.705 ± 0.036 inch)
- Outside diameter ... 13.48 mm (0.531 inch)
- Test force ... 13.4 ± 0.7 N (3.01 ± 0.15 lb)
(15) Lubricate the seal lightly with the diesel fuel.
Illustration 6 | g00368717 |
View A-A |
Illustration 7 | g00707973 |
View G-G |
(16) Lubricate the seal lightly with glycerin.
(17) Tighten the nut to the following torque. ... 8 ± 5 N·m (71 ± 44 lb in)
(18) Tighten the solenoid assembly to the following torque. ... 70 ± 10 N·m (50 ± 7 lb ft)
(19) 1N-3801 Link Spring
- Length under test force ... 26.23 mm (1.033 inch)
- Test force ... 4.5 ± 0.2 N (1.00 ± 0.05 lb)
- Free length after test ... 49.29 mm (1.941 inch)
- Outside diameter ... 11.32 mm (0.446 inch)
- Test force ... 4.5 ± 0.2 N (1.00 ± 0.05 lb)
Illustration 8 | g00707974 |
View H-H |
(20) Lubricate the seal lightly with glycerin.
(21) With the fuel rack at zero position, adjust the sensor's output (control group), as required.
(22) Torque for nut ... 55 ± 7 N·m (41 ± 5 lb ft)
Adjust the compression stroke's static timing under these conditions:
- the No. 1 Cylinder is at the TC position of the compression stroke.
- the timing slot for the fuel pump camshaft is at the TC position.
- the timing pin is installed in the timing hole inside the fuel pump housing.
Adjust the static timing to the following value:
Static timing for 3408 engines ... 19.5° before top center
Static timing for 3412 engines ... 18° before top center
Illustration 9 | g00707976 |
View D-D |
(23) Fuel outlet to secondary fuel filter
(24) Fuel inlet from primary fuel filter
Fuel Injection Pump
Illustration 10 | g01024934 |
(1) Fuel rack
- Diameter of the fuel rack ... 12.662 ± 0.005 mm (0.4985 ± 0.0002 inch)
- Bore in the fuel rack bearings after installation into the housing ... 12.767 ± 0.058 mm (0.5026 ± 0.0023 inch)
(2) Plate assembly and adapter
- Install the alignment dowels into the plate assembly to the following depth. ... 6.0 ± 0.5 mm (0.24 ± 0.02 inch)
- Install the locator pin into the adapter to the following depth. ... 6.0 ± 0.5 mm (0.24 ± 0.02 inch)
- The bore that is in the plate assembly for the adapter is the following dimension. ... 28.615 ± 0.008 mm (1.1266 ± 0.0003 inch)
- Install the locator pin into the adapter to the following depth. ... 6.0 ± 0.5 mm (0.24 ± 0.02 inch)
(3) Tighten the bushing to the following torque. ... 270 ± 13 N·m (200 ± 10 lb ft)
(4) Fuel injection pump
(5) Spacer
- Thickness of 7E-9907 Spacer ... 6.761 ± 0.005 mm (0.2662 ± 0.0002 inch)
(6) Lifter assembly
(7) Camshaft assembly
- Diameter of the bearing journals for the camshaft assembly ... 74.000 ± 0.013 mm (2.9134 ± 0.0005 inch)
- Width of the groove that is machined into the camshaft for the thrust plate ... 4.63 ± 0.05 mm (0.182 ± 0.002 inch)
- Width of the thrust plate for the camshaft ... 4.500 ± 0.025 mm (0.1772 ± 0.0010 inch)
- Width of the groove that is machined into the camshaft for the thrust plate ... 4.63 ± 0.05 mm (0.182 ± 0.002 inch)
Illustration 11 | g01024939 |
(8) Pump bonnet
(9) 8N-5993 Flow Check Spring
- Length under test force ... 11.50 mm (0.453 inch)
- Test force ... 151 ± 8 N (34 ± 2 lb)
- Free length after test ... 15.81 mm (0.622 inch)
- Outside diameter ... 10.36 mm (0.408 inch)
- Test force ... 151 ± 8 N (34 ± 2 lb)
(10) 1W-6985 Flow Check Spring
- Length under test force ... 7.63 mm (0.300 inch)
- Test force ... 8.3 ± 0.8 N (1.87 ± 0.20 lb)
- Free length after test ... 8.54 mm (0.336 inch)
- Outside diameter ... 3.2 mm (0.13 inch)
- Test force ... 8.3 ± 0.8 N (1.87 ± 0.20 lb)
(11) Retainer spring
(12) Plunger and barrel assembly
(13) 118-0540 Spring
- Length under test force ... 48.87 mm (1.924 inch)
- Test force ... 210 ± 10 N (47 ± 2 lb)
- Free length after test ... 53.87 mm (2.122 inch)
- Outside diameter ... 34.11 mm (1.343 inch)
- Test force ... 210 ± 10 N (47 ± 2 lb)
Type 2
Fuel Injection Pump and Governor
Illustration 12 | g01024999 |
(1) Tighten the bushing to the following torque. ... 163 ± 14 N·m (120 ± 10 lb ft)
(2) Governor assembly
Illustration 13 | g01025005 |
(3) The shaft seals must be flush with the face of the housing.
Illustration 14 | g01025012 |
View B-B |
(4) Tighten the nut to the following torque. ... 12 ± 4 N·m (105 ± 35 lb in)
(5) 6N-8793 Spring
- Length after assembly ... 19.05 mm (0.750 inch)
- Load at assembled length ... 2.0 ± 0.1 N (0.45 ± 0.03 lb)
- Free length after test ... 41.9 mm (1.65 inch)
- Inside diameter ... 8.38 mm (0.330 inch)
- Load at assembled length ... 2.0 ± 0.1 N (0.45 ± 0.03 lb)
(6) 4N-6681 Spring
- In order to test for the spring rate, preload the spring to 5.4 N·m (4.00 lb ft). Compress the spring for an additional distance of 22.8600 mm (0.900 inch). Total load on the spring should be the following value. ... 2.01 ± 0.65 N·m (1.48 ± 0.48 lb ft)
- Free length after test ... 56.9 ± 1.0 mm (2.24 ± 0.04 inch)
- Inside diameter ... 30.20 ± 0.38 mm (1.189 ± 0.015 inch)
- Color code ... two purple stripes
- Free length after test ... 56.9 ± 1.0 mm (2.24 ± 0.04 inch)
(7) 2W-3397 Spring
- Length after assembly ... 9.08 mm (0.358 inch)
- Load at assembled length ... 5.79 ± 0.29 N (1.30 ± 0.07 lb)
- Free length after test ... 17.34 ± 1.00 mm (0.683 ± 0.039 inch)
- Inside diameter ... 9.79 ± 0.13 mm (0.3854 ± 0.005 inch)
- Color code ... one orange stripe
- Load at assembled length ... 5.79 ± 0.29 N (1.30 ± 0.07 lb)
Prior to installing pin assembly (8), you must first align the marks that are on the gear (9), stop (10), and pinion (11).
Illustration 15 | g01025050 |
(12) Governor housing
(13) Distance between the bearings ... 2.385 ± 0.005 mm (0.0939 ± 0.0020 inch)
Illustration 16 | g01025048 |
View D-D |
(14) 7M-7316 Spring
- Length after assembly ... 43.7 mm (1.72 inch)
- Load at assembled length ... 250 to 2800 N (57 to 63 lb)
- Free length after test ... 54.76 mm (2.156 inch)
- Outside diameter ... 11.53 ± 0.13 mm (0.454 ± 0.005 inch)
- Load at assembled length ... 250 to 2800 N (57 to 63 lb)
Illustration 17 | g01025041 |
View C-C |
(15) Tighten the insulator to the following torque. ... 4.5 ± 0.5 N·m (40 ± 5 lb in)
Illustration 18 | g01025062 |
(16) Plate assembly
-
(A) The dowel should extend above the plate for the following distance. ... 7.9 ± 0.5 mm (0.31 ± 0.02 inch) (B) The dowels that are pressed through the plate should extend below the plate for the following distance. ... 5.6 ± 0.5 mm (0.22 ± 0.02 inch)
Fuel Injection Pump
Illustration 19 | g01025075 |
(1) Fuel injection pump
(2) 8N-1415 Spring
- Length under test force ... 8.69 mm (0.3421 inch)
- Test force ... 111.21 ± 6.45 N (25.001 ± 1.450 lb)
- Free length after test ... 12.12 mm (0.477 inch)
- Outside diameter ... 9.78 mm (0.385 inch)
- Test force ... 111.21 ± 6.45 N (25.001 ± 1.450 lb)
(3) 7N-1208 Spring
- Length under test force ... 29.26 mm (1.152 inch)
- Test force ... 325 ± 16 N (73 ± 4 lb)
- Free length after test ... 48.03 mm (1.891 inch)
- Outside diameter ... 25.27 mm (0.995 inch)
- Test force ... 325 ± 16 N (73 ± 4 lb)
(A) Thickness of spacers
- 9N-6496 Spacer ... 4.12 mm (0.162 inch)
- 9N-6495 Spacer ... 4.22 mm (0.166 inch)
- 5M-2697 Spacer ... 4.32 mm (0.170 inch)
- 2M-4208 Spacer ... 4.42 mm (0.174 inch)
- 2M-4209 Spacer ... 4.52 mm (0.178 inch)
- 2M-4210 Spacer ... 4.62 mm (0.182 inch)
- 2M-4211 Spacer ... 4.72 mm (0.186 inch)
- 2M-4212 Spacer ... 4.83 mm (0.190 inch)
- 5M-2691 Spacer ... 4.93 mm (0.194 inch)
- 5S-7189 Spacer ... 5.03 mm (0.198 inch)
- 9N-6495 Spacer ... 4.22 mm (0.166 inch)
(B) Dimensions for the fuel injection pump plunger
- Length of a new pump plunger ... 69.118 ± 0.013 mm (2.7212 ± 0.0005 inch)
- Minimum length of a pump plunger that may be reused ... 69.079 mm (2.7196 inch)
(C) Dimensions for the fuel rack
- Diameter of a new fuel rack ... 12.668 ± 0.005 mm (0.4987 ± 0.0002 inch)
- Bearing bore in the front of the pump housing after installation of the bearing ... 12.758 ± 0.038 mm (0.5023 ± 0.0015 inch)
- Bore in the rear of a new pump housing ... 12.758 ± 0.038 mm (0.5023 ± 0.0015 inch)
- Maximum clearance between a rack and bearings that are worn ... 0.18 mm (0.007 inch)
- Bearing bore in the front of the pump housing after installation of the bearing ... 12.758 ± 0.038 mm (0.5023 ± 0.0015 inch)
(D) Camshaft bearing journals
- Bore in the camshaft bearing after installation into the fuel pump housing ... 53.988 ± 0.038 mm (2.1255 ± 0.0015 inch)
- Diameter of the camshaft bearing journals ... 53.899 ± 0.013 mm (2.1220 ± 0.0005 inch)
- Maximum clearance between a camshaft and bearings that are worn ... 0.25 mm (0.010 inch)
- Diameter of the camshaft bearing journals ... 53.899 ± 0.013 mm (2.1220 ± 0.0005 inch)
Illustration 20 | g01025309 |
(4) Use the 5P-4158 Gauge (Fuel Injection Timing) to measure the timing dimension.
-
Install the correct spacer thickness (E) in order to obtain the necessary timing dimension (F) .
- Timing dimension with the pump on the engine ... 106.487 ± 0.051 mm (4.1924 ± 0.0020 inch)
- Timing dimension for bench test ... 110.335 ± 0.013 mm (4.3439 ± 0.0005 inch)