- a) Type and adjustment of bench injectors.
- Fuel test bench control nozzle type — DN12SD12 (NIPPONDENSO).
- The pressure at which the injector needle begins to rise is 145-155 bar.
- b) Check the error of the stand tachometer. The maximum permissible error is ±40 rpm
- c) Install the injection advance angle sensor.
- d) Secure the fuel injection pump to the stand.
Note: Place a mark on the coupling opposite the pump shaft key.
- d) Install high pressure fuel pipes with the following characteristics:
- Outer diameter: 6.0 mm
- Inner diameter: 2.0 mm
- Length: 840 mm
- Minimum allowable bending radius more than: 25 mm
- Tightening torque: 22 Nm
- e) Unscrew the fuel supply pipe union bolt.
- g) After unscrewing two bolts, remove the right cover of the injection advance unit
- h) Install a pressure gauge measuring the internal pressure in the fuel injection pump housing and a device for measuring the plunger stroke. Tightening torque: 8 Nm.
Note: Remove air using the air bleed screw.
- i) (2C-T) Connect the pressure gauge to the boost corrector.
- k) Connect the wire to the terminal of the solenoid valve of the supply cut-off and apply 12 V voltage.
Note:
- The battery should be located as far as possible from the fuel injection pump to avoid sparking.
- First connect the wire to the solenoid valve terminal.
- l) The pressure in the fuel supply pipe should be 0.2 kg/cm². The fuel temperature should be 40-45°C
- m) Install the protractor on the fuel stand and connect it to the fuel injection pump control lever.
- n) Secure the upper part of the control lever to the maximum feed position.
- o) Check the installation of the cam washer.
(1) Disconnect the high-pressure fuel pipe from the delivery fitting marked "C" on the distributor head of the high-pressure fuel pump.
(2) Using a special tool, unscrew the body (nipple) of the discharge valve.
(3) Check that fuel flows out of the distributor head hole when the mark on the adapter is positioned as shown in the figure.
(4) If fuel does not flow out, disassemble the relevant parts and turn the cam washer 180°.
Note: When performing this operation, disconnect the fuel shut-off solenoid valve terminal.
(5) Using a special tool, tighten the body (nipple) of the discharge valve. Tightening torque: 59 Nm.
(6) Install the high pressure fuel pipes. Tightening torque: 22 Nm.
- p) Remove air from the high pressure fuel lines.
- p) Let the fuel injection pump run for 5 minutes at 2000 rpm.
Note: Check for fuel leaks and abnormal noise.
Note:
- Determine the volume of fuel in measuring flasks (beakers).
- Before the next measurement, drain the fuel from the measuring cylinder for at least 30 seconds.
2. (2C-T) Check the tightness of the boost pressure corrector.
- a) Activate the boost pressure corrector by increasing the pressure to 1.22 bar within 10 s, repeat this operation 4 times.
- b) Apply 1.36 bar pressure to the boost suppression corrector.
- c) Measure the time it takes for the pressure to drop to 1.34 bar. Allowable pressure drop time: more than 10 sec.
- d) Create a vacuum of 548 mm Hg on the boost pressure corrector nipple.
- d) Measure the time it takes for the vacuum to drop to 540 mm Hg. The acceptable time for the vacuum to drop is more than 5 s.
3. Preliminary adjustment of the nominal fuel supply.
- a) Set the upper part of the fuel injection pump control lever to the maximum feed position.
- b) (2C-T) Apply 1.16 bar pressure to the boost corrector.
- c) Measure the amount of fuel supplied, (see table 1).
- d) If there is a ring seal, hold the nominal feed adjusting screw and release the sealing collar from the weld by turning the lock nut counterclockwise 90° or more.
Table 1
| Engine | Fuel injection pump drive shaft rotation speed, rpm | Number of cycles | Fuel supply, cm³ |
| 2C (M/T) | 1500 | 200 | 8,99-9,33 |
| 2C (A/T) | 1500 | 200 | 8,29-8,63 |
| 2C-T | 1500 | 200 | 11,43-11,77 |
Use a screwdriver to remove the sealing cuff.
- d) If there is a wire seal, cut the wire.
- e) Adjust the fuel supply by turning the fuel supply adjustment screw.
Note: Turning the nominal flow adjustment screw 1/2 turn changes the fuel flow by approximately 3 cm³.
4. Preliminary adjustment of the regulator shaft position.
Using a special device and an Allen key, adjust the amount of protrusion of the regulator shaft. Shaft protrusion: 0.5-2.0 mm.
5. Preliminary adjustment of maximum rotation speed.
- a) Set the fuel injection pump control lever to the maximum feed position.
- b) (2C-T) Apply 1.16 bar pressure to the boost corrector.
- c) Measure the amount of fuel supplied (see table 2).
- d) Remove the seal of the maximum speed screw
- d) Adjust the feed rate with the maximum speed adjusting screw.
Table 2
| Engine | Fuel injection pump drive shaft rotation speed, rpm | Number of cycles | Fuel supply, cm³ |
| 2C | 2700 | 200 | 2,0-3.2 |
| 2C-T | 1500 | 200 | 3.8-5.0 |
6. Adjust the fuel pressure inside the fuel injection pump housing.
- a) Set the fuel injection pump control lever to the maximum feed position.
- b) (2C-T) Apply 1.16 bar pressure to the boost corrector.
- c) Measure the fuel pressure inside the fuel injection pump housing at the rotation speeds specified in Table 3.
- d) If the pressure is less than the specified values, then adjust it using a metal rod by lightly tapping the stop of the pressure reducing valve spring, while simultaneously observing the readings of the pressure gauge measuring the pressure inside the fuel injection pump housing.
Table 3
| Engine | Fuel injection pump drive shaft rotation speed, rpm | Internal pressure, kg/cm² |
| 2C | 600 | 2,7-3,3 |
| 2C | 2100 | 6,47-7,07 |
| 2C-T | 600 | 3,3-3,9 |
| 2C-T | 2500 | 7,8-8,4 |
If the pressure exceeds the specified values or if the pressure reducing valve is stuck, it must be replaced.
7. Check the fuel volume.
- a) Set the fuel injection pump control lever to the maximum feed position.
- b) (2C-T) Apply 1.16 bar pressure to the boost corrector.
- c) Measure the volume of fuel supplied through the fuel return hose from the high-pressure fuel pump housing at the rotation speeds specified in Table 4.
Table 4
| Engine | Fuel injection pump drive shaft rotation speed, rpm | Volume of fuel discharged, cm³ |
| 2C | 2100 | 167-364 |
| 2C-T | 2250 | 367-800 |
Note: Always install the fuel return line mounting bolt that was installed on the injection pump.
8. For the following adjustments, turn off the engine warm-up control device.
- a) Turn the heating control lever 20° counterclockwise.
- b) Place a 8.5-10mm metal plate between the lever and the heating control actuator.
Note: Keep the warm-up overspeed system disabled until all measurements and adjustments have been made.
9. Measure and adjust the stroke of the injection advance plunger.
- a) Set the plunger stroke measurement scale to zero.
- b) (2C-T) Apply 1.16 bar pressure to the boost corrector.
- c) Measure the stroke of the injection advance plunger at the specified rotation speeds.
Table 5
| Engine | Fuel injection pump drive shaft rotation speed, rpm | Plunger stroke, mm |
| 2C manual transmission | 600 | 0,88-1,88 |
| 1500 | 5,02-6,02 | |
| 2100 | 7,78-8,78 | |
| 2C automatic transmission | 600 | 0,68-1.68 |
| 1500 | 4,92-5,92 | |
| 2100 | 7,75-8,75 | |
| 2C-T | 600 | 0,90-1,90 |
| 1300 | 3,69-4,69 | |
| 1800 | 5,69-6,69 | |
| 2350 | 6,32-6,80 |
- d) Using a 5 mm Allen key, adjust the stroke of the advance mechanism plunger.
Note: The plunger stroke decreases when the screw is turned clockwise and increases when the screw is turned counterclockwise.
- d) (2C-T) Check the characteristics of the injection advance spring.
- e) (2C-T) If the characteristic differs from the specified one, select and replace the inner spring.
Free spring length 31.9 mm; 32.0 mm; 32.2 mm; 32.3 mm; 32.5 mm.
Note; the stroke of the advance piston increases with the lengthening of the spring.
10. Adjustment of cyclic feed at full load.
- a) Angle of rotation of the regulator lever: (A - maximum idle speed) — plus 13-23°, (B - minimum idle speed) minus 24-34°.
- b) (2C-T) Apply 1.16 bar pressure to the boost corrector.
- c) Measure the cyclic flow at full load (see table 1 above).
- d) Adjust the fuel supply at full load with the nominal supply adjusting screw.
Note: The feed rate changes by approximately 3 cm³ for every half turn of the screw.
11. Adjustment at maximum speed.
- a) (2C-T) Apply 1.16 bar pressure to the boost corrector;
- b) Measure the volume of injected fuel at maximum engine speed values.
Table 6
| Engine | Fuel injection pump drive shaft rotation speed, rpm | Fuel supply, cm³ |
| 2C | 2600 | 4,5-6,3 |
| 2700 | 2,0-3,2 | |
| 2950 | 0.7 or less | |
| 2C-T | 2500 | 3,8-5,0 |
| 2600 | 5,86-8,26 | |
| 2900 | 0.7 or less |
Number of cycles: 200
Angle of rotation of the fuel injection pump control lever: plus 13 - 23°
- c) Adjust the volume of fuel injected using the maximum speed adjusting screw.
12. Check the volume of injected fuel.
- a) Measure the volume of injected fuel at the rotation speed and pressure on the boost corrector specified in Table 7.
Number of cycles: 200.
Angle of rotation of the fuel injection pump control lever: plus 13-23°
For 2C-T, the pressure on the boost corrector:
- at 100 rpm: 0 bar
- for others: 1.16 bar
Table 7
| Engine | Fuel injection pump drive shaft rotation speed, rpm | Fuel supply, cm³ | Permissible unevenness, cm³ |
| 2C manual transmission | 100 | 8,6 - 13,4 | 1,2 |
| 500 | 7,87-8,77 | 0,5 | |
| 1500 | 8,99-9,33 | 0,4 | |
| 2350 | 7,61-8,51 | 0,5 | |
| 2500 | 6,93-8,19 | 0,5 | |
| 2C automatic transmission | 100 | 8,6-13,4 | 1,2 |
| 500 | 6,81-7,71 | 0,5 | |
| 1500 | 8,29-8,63 | 0,4 | |
| 2350 | 7,19-8,09 | 0.5 | |
| 2500 | 6,39-7,65 | 0,5 | |
| 2C-T | 1500 | 11,43-11,77 | 0,4 |
| 100 | 9.6-14,4 | 1,2 | |
| 2100 | 9,66-10,56 | 0,5 | |
| 2250 | 8,8-10,06 | 0,5 |
- b) If the starting feed rate (at a speed of 100 rpm) does not correspond to the table value, then replace the regulator bushing plug: Press the plug out of the regulator bushing.
- c) Remove the following parts: 1 - retaining ring, 2 - thrust ring, 3 - thrust bearing, 4 - plug.
- d) Measure the thickness of the bushing plug head, select a new bushing plug. Note: 0.1 mm longer plug increases the starting flow by 0.6 cm³/200 cycles. If the flow irregularity exceeds the specified value, replace the delivery valve.
The plugs are available with different head thicknesses (with a step of 0.1 mm):
- 2C from 2.2 to 3.4 mm
- 2C-T from 3.0 to 4.2 mm
- d) Assemble the regulator sleeve in the reverse order of disassembly, press the plug into the sleeve.
13. (2C-T) Adjustment of minimum feed at full load.
- a) Set the fuel injection pump control lever to the maximum position.
- b) Release the pressure on the boost corrector.
- c) Measure the fuel supply at a fuel injection pump drive shaft speed of 700 rpm and a number of cycles of 200. Fuel supply: 6.8-7.4 cm³.
- b) The feed rate is changed by turning the stop of the stroke limiter of the corrector rod.
14. (2C-T) Boost pressure adjustment.
A. Adjusting the boost corrector characteristics.
- a) Set the fuel injection pump control lever to the maximum feed position.
- b) Apply 0.34 bar pressure to the boost corrector.
- c) Measure the fuel supply at a fuel injection pump drive shaft speed of 700 rpm and a number of cycles of 200. Fuel supply: 7.4-8.2 cm³.
- d) Remove the manifold drain pin and gasket.
- e) Adjust the fuel supply by turning the corrector rod guide sleeve (turning clockwise increases the fuel supply.
- e) Install a new gasket and the corrector drain screw.
B. Checking the slope of the boost corrector characteristic
- a) Set the fuel injection pump control lever to the maximum position.
- b) Apply 0.86 bar pressure to the boost corrector.
- c) Measure the fuel supply at a fuel injection pump drive shaft speed of 700 rpm and a number of cycles of 200. Fuel supply 10.26-11.05 cm³.
B. Measure the hysteresis. Compare the cyclic fuel feeds when the pressure on the corrector increases from 0 to 1.36 bar and when the pressure decreases from 1.36 bar to 0. See Table 6.
Table 8
| Fuel injection pump drive shaft rotation speed, rpm | Boost corrector pressure, bar | Fuel supply, cm³ | Hysteresis, cm³ |
| 1500 | 1,36 | 12.0 or less | 0,5 |
| 1500 | 1,22 | 11,30-11 90 | 0,5 |
| 700 | 0,88 | 10,26-11,06 | 0,5 |
| 700 | 0,34 | 7,40-8,20 | 0,5 |
| 700 | 0 | 6,80-7,40 | 0,3 |
Note: when taking a characteristic when the pressure drops, turn the fuel injection pump control lever from the idle position towards the maximum mode. Take measurements three times for each case.
Number of cycles - 200.
The angle of rotation of the fuel injection pump control lever is plus 13-23°
If there is increased hysteresis, check the quality of the corrector assembly and the presence of sufficient lubrication.
Characteristics of the boost corrector: a - adjust the cyclic feed, b - adjust the minimum feed in full load mode, c - adjust the starting feed during cold start, d - adjust the boost pressure corrector characteristic, d - adjust the slope of the boost pressure corrector characteristic.
15. Adjust the position of the regulator shaft according to the load.
- a) Adjustment is made by turning the shaft of the regulator sleeve. Adjust the starting and ending points of the speed regulator clutch stroke.
- b) Set the fuel injection pump control lever to the maximum feed position.
- c) (2C-T) Apply 0.41 bar pressure to the boost corrector.
- d) Measure the fuel supply.
Number of cycles 200
Rotation speed: 2C 1500 rpm; 2C-T 1800 rpm.
- d) Slowly move the lever to the minimum idle stop and secure the lever at the point where the pressure in the pump body begins to drop.
- y) Measure the flow rate at the point where the pressure starts to drop. Calculate the difference in flow rates and compare with the data in the table.
Table 9
| Engine | Rotation speed, rpm | Number of cycles | Feed difference, cm³ |
| 2C | 1500 | 200 | 1,0±0,3 |
| 2C-T | 1800 | 200 | 1,0±0,3 |
- g) Adjust the feed difference by turning the regulator shaft.
Note: Half a turn of the regulator shaft changes the feed by 3 cm.
- h) Slowly move the lever to the minimum idle stop and secure the lever at the point where the pressure in the pump body stops dropping.
Compare the fuel supply value with the data in Table 10.
- i) Check the difference in the injection advance plunger stroke by load when moving the fuel injection pump control lever from the maximum speed position to the idle position. See Table 11.
- k) (2C-T) If the difference in the stroke of the injection advance plunger does not correspond to the values specified in the table, then select a new bushing with a hole of the required diameter.
Note: Increasing the bore diameter increases the stroke difference.
Table 10
| Engine | Fuel injection pump drive shaft rotation speed, rpm | Fuel supply, cm³ |
| 2C manual transmission (with EGR system) | 1500 | A-2.7±0.3 |
| 2C manual transmission (without EGR system) | 1500 | A-2.5±0.3 |
| 2C automatic transmission | 1500 | A-2.3±0.3 |
| 2C-T | 1800 | A-2.3±0.3 |
Note: where A is the value measured in subparagraph c) of paragraph 15.
Table 11
| Engine | Fuel injection pump drive shaft rotation speed, rpm | Plunger stroke difference, mm |
| 2C manual transmission (with EGR system) | 1500 | 2,16-2.76 |
| 2C manual transmission (without EGR system) | 1500 | 1,75-2,35 |
| 2C automatic transmission | 1500 | 1,34-1,94 |
| 2C-T | 1800 | 1,34-1,94 |
- l) Measure the regulator shaft protrusion. Shaft protrusion 0.5-2.0 mm.
16. Adjusting the idle speed.
- a) (2C-T) Loosen the damper control lever bolt.
- b) Measure the feed at different speeds of the injection pump drive shaft. (See table 12).
Table 12
| Engine | Fuel injection pump drive shaft rotation speed, rpm | Fuel supply, cm³ | Note |
| 2C | 400 | q = 1,65.-2,55 | adjust |
| 475 | q - (1,2...2,2) | - | |
| 375 | q + 0.5 or more | - | |
| 2C-T | 400 | q = 2,05...2,95 | adjust |
| 600 | q - (1,2...2,2) | - | |
| 375 | q + 0.5 or more | - |
Angle of rotation of the fuel injection pump control lever: minus 24-34°.
Number of cycles: 200.
Permissible unevenness: 0.34 cm³.
- c) Adjust the fuel injection rate at minimum idle speed using the minimum idle speed adjusting screw.
17. (2C-T (modifications)) Adjust the damper.
- a) Install a metal plate between adjusting lever No.1 and the idle speed adjusting screw.
- b) Move the damper control lever until it touches the damper rod.
- c) Secure the lever with a bolt. Tightening torque: 8 Nm.
- d) Check that the damper rod does not press on the damper control lever.
18. Adjust the heating control system.
- a) Loosen the fuel return pipe mounting bolt and measure the fuel temperature inside the fuel injection pump housing. Fuel temperature: 15-35°C.
- b) Install the fuel injection pump drive shaft so that the woodruff key is in a vertical or horizontal position.
- c) Set the scale of the device for measuring the stroke of the injection advance plunger to zero.
- d) Check the initial angular position of the fuel injection pump heating control lever, which we will consider as zero.
- d) Remove the metal plate that was installed between the adjusting lever and the heating control drive.
- e) Turn the automatic heating control lever clockwise with a force of approximately 4.9 Nm and hold it in this position with a torque wrench at the specified force for 10 seconds, then release the force.
- g) Measure the stroke of the injection advance plunger at a temperature of 25°C and a fuel injection pump drive shaft speed of 400 rpm.
Plunger stroke:
- 2C with manual transmission 0.74-1.14 mm
- 2C with automatic transmission 0.55 - 0.95 mm
- 2C-T 0.91 - 1.31 mm
If it is not within specification, adjust it using the adjusting screw.
19. Adjust the high idle speed.
2C
- a) Measure the clearance between the control lever and the idle speed adjusting screw.
Clearance at fuel temperature: 25°C 1.4 mm; 50°C 0 mm.
- b) Adjust the clearance by turning the high idle speed adjusting screw.
2C-T
- a) For the following adjustments, turn off the engine warm-up control device.
- Turn the heating control lever 20° counterclockwise.
- Place a 8.5-10mm metal plate between the lever and the heater control actuator.
- b) Set the control lever to the idle position.
- c) Measure the injected fuel supply at a fuel injection pump drive shaft speed of 400 rpm and a number of cycles of 200. Fuel supply q = 2.05-2.95 cm³
- d) Remove the metal plate between the lever and the heating control drive.
- d) Turn the automatic heating control lever clockwise with a force of approximately 4.9 Nm and hold it in this position with a torque wrench under the specified force for 10 seconds, then remove the force.
- c) Measure the fuel supply at a fuel injection pump drive shaft speed of 400 rpm and a number of cycles of 200. Fuel supply q plus 1.5-1.9 cm³.
- g) Adjust the fuel supply by turning the high idle speed adjusting screw.
20. (2C-T) Adjust the increase in idle speed when the air conditioner is turned on.
- a) For the following adjustments, turn off the engine warm-up control device.
- Turn the heating control lever 20° counterclockwise.
- Place a 8.5-10mm metal plate between the lever and the heater control actuator.
- b) Create a vacuum of 300 mm Hg in the idle speed increase drive system when the air conditioner is turned on.
- c) Set the control lever to the idle position.
- d) Measure the injected fuel supply at a fuel injection pump drive shaft speed of 450 rpm and a number of cycles of 200. Fuel supply 1.8-2.6 cm³
- d) Adjust the fuel supply by turning the idle speed increase drive system adjusting screw when the air conditioner is turned on.
If you cannot adjust it with the screw, adjust it with the adjusting washers.
- e) Remove the metal plate between the lever and the heating control actuator.
21. Checking after adjustment.
- a) Check that the supply stops when the fuel shut-off solenoid valve is disconnected. High-pressure fuel pump shaft speed: 100 rpm.
- b) (2C-T) For the following adjustments, turn off the engine warm-up control device.
- Turn the heating control lever 20* counterclockwise.
- Place a 8.5 - 10 mm metal plate between the lever and the heating control actuator.
- c) Check the movement of the control lever. The adjustment angle of the control lever position is 42-52°.
- d) Remove the metal plate between the lever and the heating control drive.
22. Adjust the control lever position sensor.
- a) Set the control lever to the position corresponding to the volume of fuel injected, shown in Table 13. Number of cycles: 200.
Table 13
| Engine | Fuel injection pump drive shaft rotation speed, rpm | Fuel supply, cm³ |
| 2C | 700 | 5,6 |
| 2C-T | 1000 | 5,12-5,28 |
- b) Loosen the two screws securing the control lever position sensor to the bracket.
- c) Apply 5V voltage between terminals "VC" and "E2".
- d) Connect the voltmeter to the "VTA" and "E2" terminals of the control lever position sensor.
- d) Smoothly turn the control lever position sensor so that the output voltage becomes: 2C: 2.14±0.025 V; 2C-T: 2.97±0.025 V.
23. Remove the fuel injection pump from the stand.
24. Install seals. Seal the maximum speed and nominal feed adjustment screws (full load) with new wire seals.
