GROUP 13A

FUEL AND ENGINE CONTROL

SPECIFICATIONS ............................................................................ 13A-2

STRUCTURE AND OPERATION

1. Fuel System (Fuel Flow) ............................................................ 13A-3
2. Engine Control .......................................................................... 13A-4
3. Fuel Filter .................................................................................. 13A-5
4. Injection Nozzle ......................................................................... 13A-6

TROUBLESHOOTING ..................................................................... 13A-8

ON-VEHICLE INSPECTION AND ADJUSTMENT

1. Inspecting and Adjusting No-load Minimum
and Maximum Speeds.............................................................. 13A-10
2. Air-bleeding of Fuel System ......................................................... 13A-11
3. Fuel Filter Replacement ........................................................... 13A-11

FUEL TANK.................................................................................... 13A-12

FUEL FILTER ................................................................................. 13A-14

ENGINE CONTROL ....................................................................... 13A-16

INJECTION PUMP ......................................................................... 13A-20

INJECTION NOZZLE ..................................................................... 13A-24

13A-1
SPECIFICATIONS
Item Specifications
Manufacturer BOSCH AUTOMOTIVE SYSTEMS
Model VP 44
Electronically controlled distributor type pump (with built-in-
Type
pump control unit)
Injection pump Maximum pump pressure
Approx. 100 {1000}
MPa {kgf/cm2}
Timer Oil pressure type
Timer control valve Duty solenoid type
Feed pump Vane type
Manufacturer BOSCH AUTOMOTIVE SYSTEMS
Type Hole-type (2-spring)
Injection nozzle
No. of holes 5
Hole diameter mm φ 0.18
Fuel filter type Spin-on type (paper filter)
Fuel filter Water level alarm Provided
Priming pump Provided

13A-2
STRUCTURE AND OPERATION 13A
1. Fuel System (Fuel Flow)

• Fuel in the fuel tank is drawn up by the feed pump which is driven by the drive shaft of the VP44 injection pump.
The fuel is strained through the fuel filter and delivered into the VP44 injection pump.
• The VP44 injection pump pressurizes and feeds the fuel to the injection nozzle, through which the fuel is sprayed
into the combustion chamber.
• Excess oil which has overflowed from the injection nozzle returns through the fuel leak-off pipe to the fuel tank.
• Furthermore, if the fuel pressure in the VP44 injection pump exceeds a preset level, the overflow valve opens to
allow excess fuel to return through the fuel return pipe to the fuel tank.

13A-3
STRUCTURE AND OPERATION
2. Engine Control
• The engine is electronically controlled
by the engine electronic control unit
(ECU). (See Gr 13E.)
• The accelerator pedal position sensor
detects the movement of the accelera-
tor pedal and sends an accelerator
pedal position signal to the engine
ECU. Based on this signal, the engine
ECU controls the fuel injection system
to inject the optimum amount of fuel.

13A-4
 13A
3. Fuel Filter

The fuel filter, which also serves as a water separator, removes foreign particles in the fuel and separates water in
the fuel at the same time. The water separated from the fuel is collected in the bottom part of the filter. When the wa-
ter level reaches a certain point, the water level sensor, which is installed to the filter bottom, is activated to turn on
the warning lamp in the meter cluster. To drain out the collected water, the water level sensor is loosened and the
drain hole is unplugged. A hand priming pump is provided on top of the fuel filter head for bleeding air from the fuel
system.

13A-5
STRUCTURE AND OPERATION
4. Injection Nozzle

• Inside the nozzle, a pre-lift distance is provided between the lift piece and spring seat B. The nozzle’s injection
start pressure is determined by the force of the 1st spring.
• When the pressure of fuel fed from the injection pump, i.e., the pressure in the nozzle tube, overcomes the 1st
spring, the needle valve moves upward by the pre-lift distance. At this time, force is transmitted in the sequence
shown below to the extent that the 1st spring is pushed upward.
• Force transmission sequence:
Needle valve → Lift piece → Push rod → Spring seat A → 1st spting
• When the lift piece moves upward by the pre-lift distance, it makes contact with the spring seat B. With the lift
piece and spring seat B touching each other, the spring force at this time is equivalent to the combined force of
the 1st spring and 2nd spring. Thus, the needle valve momentarily stops lifting.
• As the fuel pressure, i.e., the pressure in the nozzle tube, increases further and overcomes the combined force of
the two springs, the needle valve lifts again for the main injection. At this time, force is transmitted in the sequence
shown below such that the 2nd spring is pushed upward.
• Force transmission sequence:
Needle valve → Lift piece → Spring seat B → 2nd spting

13A-6
 13A
M E M O

13A-7
TROUBLESHOOTING
Symptoms

Engine does not reach maximum speed

Engine maximum speed too high

Engine stops soon after starting

Accelerator pedal too stiff

Engine output insufficient
Reference

Engine output unstable

Engine difficult to start

Engine idling unstable

warning lamp on
Engine does not start

Engine does not stop

Gr

Fuel supply poor

Engine knocks
Possible causes
Electronically controlled fuel system faulty O Gr13E

Injection pump
Pump faulty O O O O O O O O O O O O
*
Overflow valve faulty O O O O O O O O
*
Needle valve stuck O
Valve opening pressure too low O O
Injection orifice clogged O O O O O O
Nozzle not airtight O O O O O
Injection
Valve opening pressure too high O
nozzle
Spring broken O O O
Needle valve sliding action poor O
Valve opening pressure poor O
Spring fatigued O O O
Fuel filter clogged O O O O
Fuel tank empty O
Fuel pipe blocked and/or fuel leaking from connections O O O
Air or water in fuel system O O O O
Low-quality fuel in use O O O O O
Accelerator pedal stopper bolt incorrectly ad-
O O O O O
Engine control justed
Accelerator pedal position sensor faulty O O O O O
Fuel hose or pipe cracked O
Fuel tank not airtight O
Oil viscosity incorrect O O Gr12
Valve clearance incorrect O O
Cylinder head gasket defective O O
Wear and/or carbon deposits on valve and valve seat O O
Valve spring fatigued O O Gr11
Piston ring worn or damaged O O
Piston ring groove worn or damaged O
Piston and cylinder liner worn O O
Cooling system malfunctioning O O Gr14

* Ask a BOSCH AUTOMOTIVE SYSTEMS service station to do the job.

13A-8
 13A
Symptoms

Engine does not reach maximum speed

Engine maximum speed too high

Engine stops soon after starting

Accelerator pedal too stiff

Engine output insufficient
Reference

Engine output unstable

Engine difficult to start

Engine idling unstable

warning lamp on
Engine does not start

Engine does not stop

Gr

Fuel supply poor

Engine knocks
Possible causes
Starting switch faulty O
Gr54
Glow relay faulty O
Engine speed sensor or backup engine speed sensor open circuit-
O O O
ed, short circuited or in poor contact
Boost pressure sensor open-circuited, short circuited or in poor
O O O O O
contact
Coolant temperature sensor open-circuited, short-circuited or in
O O O
poor contact
Injection quantity adjusting resistor in poor contact O O
Main relay faulty or fuse burned out O O O

13A-9
ON-VEHICLE INSPECTION AND ADJUSTMENT
1. Inspecting and Adjusting No-load Minimum and Maximum Speeds

Service standards
Location Maintenance item Standard value Limit Remedy
When idling at ordinary speed 750 ± 25 rpm – Adjust
When air condi-
900 ± 50 rpm – Adjust
Minimum no-load tioner operating
– When idling at
speed
increased speed When warming
up system oper- 900 ± 50 rpm – Adjust
ating
– Maximum no-load speed 3700 rpm – Adjust

[Work before inspection and adjustment]

• Before starting the inspection and adjustment, carry out the fol-
lowing preparatory steps:
• Warm up the engine until the engine coolant temperature is ap-
proximately 80 to 95°C;
• Turn off all lamps and accessories;
• Put the transmission in neutral;
• Set the steering wheel at the straight-ahead position; and
• Attach a tachometer.

[Inspection]
(1) No-load minimum speed
• Without pressing the accelerator pedal, measure the engine
speed.
• If the measurement is not within the standard value range, in-
spect the accelerator position sensor and accelerator switch.
(See Gr13E.)
• If no defects are evident during the above inspection, check for
any diagnosis code related with the fuel system and inspect the
injection pump and engine electronic control unit. (See Gr13E.)

(2) No-load maximum speed

• Press the accelerator pedal as far as it will go.
• With the accelerator pedal touching the stopper bolt, measure
the engine speed.
• If the measurement is not within the standard value range, in-
spect the accelerator position sensor and accelerator switch.
(See Gr13E.)
• If no defects are evident during the above inspection, check for
any diagnosis code related with the fuel system and inspect the
injection pump and engine electronic control unit. (See Gr13E.)

13A-10
 13A
2. Air-bleeding of Fuel System
Tightening torque (Unit: N·m {kgf·m})
Mark Parts to be tightened Tightening torque Remarks
– Air vent plug 6 ± 1 {0.6 ± 0.1} –

• Loosen the air vent plug of the fuel filter.

• Move the priming pump up and down to pump out the fuel.
• Continue operating the priming pump until the fuel flowing out of
the air vent plug is free of air bubbles.
• When no more air bubbles are evident, tighten the air vent plug
to the specified torque.
• Operate the priming pump further until a strong resistance can
be felt.
• Wipe up any spilled fuel and start the engine.
• Check that there is no fuel leakage.
WARNING
• Fuel is highly flammable. Keep it away from flames and
sources of heat.
• To avoid risk of fire, wipe up any spilled fuel.

3. Fuel Filter Replacement

Lubricant and/or sealant
Mark Points of application Specified lubricant and/or sealant Quantity
– Fuel filter gasket Engine oil As required

WARNING
• Be sure to use only genuine MITSUBISHI filter cartridges.
Use of non-genuine fuel filters can cause fuel leakage and
fire.

CAUTION
• Prevent fine dust particles from entering the fuel filter and
fuel pipe, as they can cause problems such as faulty fuel in-
jection.

• Clean the fuel filter mounting surface of the fuel filter head.
• Apply a thin coat of engine oil to the fuel filter gasket.
• Screw the fuel filter cartridge into the filter head by hand until its
gasket comes into contact with the head. Then, tighten the car-
tridge further by a three-quarter turn.
• Install the water separator sensor, and then air-bleed the fuel
system.
• Start the engine, and check that there is no fuel leakage from the
gasket.
• Reinstall the fuel filter cartridge if there is any leakage.

13A-11
FUEL TANK
Removal sequence
1 Drain plug
2 Suction hose
3 Return hose
4 Air vent tube
5 Fuel level sensor
6 Fuel tank band
7 Fuel tank
8 Fuel tank bracket

Installation sequence
Follow the removal sequence in reverse.

WARNING
• Fuel is highly flammable. Keep it away from flames and sources of heat.
• To avoid risk of fire, wipe up any spilled fuel.

DANGER
• Do not allow any flames or sources of heat near the fuel tank, as it may explode.

NOTE
• Insert the air vent tube into the bracket, taking care not to pinch or break the air vent tube with the fuel
tank band.

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Drain plug 14.7 ± 24.5 {1.5 ± 2.5} –
Screw (fuel level sensor mounting) 1.0 to 1.5 {0.10 to 0.15} –
Locknut (fuel tank band mounting) 9 to 14 {0.9 to 1.4} –
Nut (fuel tank band mounting) 4 to 8 {0.4 to 0.8} –
Bolt (fuel tank bracket mounting) 70 to 90 {7.1 to 9.2} –

13A-12
 13A
M E M O

13A-13
FUEL FILTER
Disassembly sequence
1 Fuel hose
2 Water separator sensor
3 O-ring
4 Fuel filter cartridge
5 Air vent plug
6 Fuel filter head

: Non-reusable parts

Assembly sequence
Follow the disassembly sequence in re-
verse.

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Water separator sensor 2.5 ± 0.5 {0.3 ± 0.05} –
Air vent plug 6 ± 1 {0.6 ± 0.1} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
– Fuel filter gasket Engine oil As required

13A-14
 13A
Installation procedure
Installation: Fuel filter
WARNING
• Be sure to use only genuine MITSUBISHI filter cartridges.
Use of non-genuine fuel filters can cause fuel leakage and
fire.

CAUTION
• Prevent fine dust particles from entering the fuel filter and
fuel pipe, as they can cause problems such as faulty fuel in-
jection.

• Clean the fuel filter mounting surface of the fuel filter head.
• Apply a thin coat of engine oil to the fuel filter gasket.
• Screw the fuel filter cartridge into the filter head by hand until its
gasket comes into contact with the head. Then, tighten the car-
tridge further by a three-quarter turn.
• Install the water separator sensor, and then air-bleed the fuel
system.
• Start the engine, and check that there is no fuel leakage from the
gasket.
• Reinstall the fuel filter cartridge if there is any leakage.

13A-15
ENGINE CONTROL
Removal sequence
1 Accelerator pedal (See later sec-
tions.)
2 Accelerator link (See later sec-
tions.)
Installation sequence
Follow the removal sequence in reverse.

Removal procedure
Removal: Accelerator pedal
• Using pliers, pinch the hook of the stopper on the accelerator
pedal. Separate the stopper from the pedal while turning the
hook by about 15 degrees.
CAUTION
• Do not yank on the stopper, as this may damage it.

Installation procedure
Installation: Accelerator pedal
• Press the accelerator pedal until the accelerator lever touches
the accelerator link stopper bolt.
• Check that the clearance between the stopper and the stopper
bolt contact surface of the pedal is as indicated in the illustration.
• If the clearance is not within the indicated value range, adjust
the stopper bolt and lock it with the nut.

13A-16
 13A
Accelerator Pedal
Disassembly sequence
1 E-ring
2 Clevis pin
3 Accelerator pedal
4 Stopper bolt
5 Accelerator pedal bracket

Assembly sequence
Follow the disassembly sequence in re-
verse.

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Accelerator pedal and bracket contact surfaces Chassis grease [NLGI No. 1 (Li soap)] As required

13A-17
ENGINE CONTROL
Accelerator Linkage
Disassembly sequence
1 Cover
2 Spring
3 Washer
4 Bushing
5 Return spring
6 Accelerator lever
7 Accelerator position sensor and
accelerator switch assembly
8 Lever stopper
9 Rubber stopper
10 Accelerator link bracket

Assembly sequence
Follow the disassembly sequence in re-
verse.
NOTE
• For the inspection and adjustment
of accelerator position sensor, see
Gr13E.

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Accelerator lever and return spring sliding surface Chassis grease [NLGI No. 1 (Li soap)] As required

13A-18
 13A
M E M O

13A-19
INJECTION PUMP

Disassembly sequence
1 Fuel leak-off hose 7 Plug *a: Front plate
2 Fuel return hose 8 Injection pump assembly
*b: Vacuum pump
3 Fuel feed hose 9 O-ring
*c: Timing gear case
4 Injection pipe 10 Upper rubber spacer
5 Pump stay 11 Lower rubber spacer : Non-reusable parts
6 Pump bracket

13A-20
 13A
WARNING
• Fuel is highly flammable. Keep it away from flames and sources of heat.
• Wipe off spilled fuel completely. It could catch fire.

CAUTION
• For maintenance of the injection pump assembly, contact a BOSCH AUTOMOTIVE SYSTEMS service sta-
tion.
• Dirt particles in the injection pump assembly can seriously detract from engine performance. To prevent
ingress of dirt, cover all pipes, hoses and other parts after removal.

Assembly sequence
Follow the disassembly sequence in reverse.

CAUTION
• Before installing the injection pipe, make sure that the pipe seating surface is free from damage and un-
evenness.

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Injection pipe 23 {2.3} –
Plug 39 {4.0} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
O-ring Engine oil As required

Special tools
Mark Tool name and shape Part No. Application

Front hub and flange

MB990767
yoke holder

Turning crankshaft pulley

Crankshaft pulley holder

MD998754
pin

13A-21
INJECTION PUMP
Removal procedure
Removal: Injection pipe
Lock the delivery valve holder to prevent it from rotating together.
Then, loosen the union nut to remove the injection pipe.

Removal: Injection pump

Using the and , turn the crankshaft pulley clockwise to
bring No. 1 piston to the top dead center of its compression stroke.
Then, align the notch in the crankshaft pulley with the timing mark
“0” on the timing gear case.

CAUTION
• Never rotate the crankshaft pulley counter-clockwise. The
timing chain tensioner could be damaged. If the crankshaft
has been rotated counter-clockwise, remove and reinstall
the tensioner after checking for damage. See Gr11.

NOTE
• If the projections of the camshafts are both on top, No. 1
piston is at the top dead center of its compression stroke. If
not, give one more clockwise turn to the crankshaft pulley.
Assemble the hexagon socket head bolt to the injection pump gear
from the plug mounting hole of the timing gear case to secure the
injection pump gear and the injection pump sub gear.

13A-22
 13A
Installation procedure
Installation: Injection pump
• Bring No. 1 cylinder to the top dead center (TDC) on the com-
pression stroke.
• Align the notch in the injection pump gear with the alignment
mark on the flange plate.

• Insert the guide bar of the flange plate in the guide hole of the
front plate. Then, press in the injection pump gear to the point
just short of engaging with the idler gear.

• Make sure that the alignment mark on the flange plate is in align-
ment with the notch in the injection pump gear, then press the in-
jection pump assembly further into place. The notch should
move in the direction as illustrated.

• After installing the injection pump assembly, remove the hexa-

gon socket head bolt.

Installation: Injection pipe

• Install the injection pipe by following the removal instructions.
(See “ Removal: Injection pipe”.)

13A-23
INJECTION NOZZLE

Disassembly sequence
1 Injection pipe 11 Lift piece 21 Spring seat
2 Injection pipe seal 12 Spacer 22 1st spring
3 Eyebolt 13 Pin 23 Shim
4 Return pipe 14 Needle valve 24 O-ring
5 Eyebolt 15 Nozzle 25 Nozzle holder
6 Gasket 16 Spring seat 26 O-ring
7 Eyebolt 17 Shim 27 Nozzle gasket
8 Leak-off pipe 18 2nd spring
9
10
Injection nozzle
Retaining nut
19
20
Push rod
Collar
*a:: Cylinder head
Non-reusable parts

Assembly sequence
Follow the disassembly in reverse.

WARNING
• Fuel is highly flammable. Keep it away from flames and sources of heat.
• Wipe off spilled fuel completely. It could catch fire.

13A-24
 13A
CAUTION
• Clean off all carbon deposits before disassembling, reassembling or adjusting the injection nozzle as-
sembly. Prior to intended disassembly, check the injection nozzle assembly for abnormal injection pres-
sure, abnormal spray pattern and fuel leaks. Do not disassemble if no abnormality is evident.
• Under no circumstance change the combination of the needle valve and nozzle in each injection nozzle
assembly.
• Dirt particles can seriously detract from engine performance. To prevent the ingress of dirt, cover the noz-
zle mounting hole after each injection nozzle assembly is removed.

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy
18.6 ± 0.5 MPa
Injection pressure (valve 1st valve opening pressure –
{190 ± 5 kgf/cm2}
opening pressure) of Adjust
injector assembly 22.6 ± 0.5 MPa
2nd valve opening pressure –
{230 ± 5 kgf/cm2}
9 Replace with part
Pre-lift 0.06 ± 0.01 – in nozzle service
kit
Replace with part
Needle valve lift 0.25 ± 0.02 – in nozzle service
kit

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Injection pipe 29 {3.0} –
Eyebolt (return pipe mounting)
9.8 {1.0} –
Eyebolt (leak-off pipe mounting - head side)
Eyebolt (leak-off pipe mounting - nozzle side) 10 to 15 {1 to 1.5} –
Bolt (injection nozzle assembly mounting) 21 {2.1} –
Retaining nut 29 to 39 {3 to 4} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
O-ring Engine oil As required

Special tools
Mark Tool name and shape Part No. Application
Plate *157944-9520 Retaining nozzle holder
Nozzle cleaning tool *105789-0010 Cleaning injection nozzle assembly
Gasket *157892-3200 For retaining nut
– Retaining nut for adjustment *157892-5120
2
* Retaining nut for adjustment *157892-5100
2
* Gasket *026508-1140 For plug
2
* Plug *157892-1600
– Adjusting device *157892-4420
*1 Holder *157892-4400
1
* Nut *157892-1000 Holding dial gauge in place
Dial gauge *157954-3801
Pin *157892-7200 L = 92 mm

*: BOSCH AUTOMOTIVE SYSTEMS part numbers

*1: Components of adjusting device 157892-4420
*2: Components of retaining nut 157892-5120 for adjustment

13A-25
INJECTION NOZZLE
Inspection before removal
Inspection: Injection nozzle
Fit the injection nozzle assembly onto the nozzle tester to be ready
for inspection.

NOTE
• Before starting inspection, operate the lever of nozzle tester
A two or three times to bleed all air out from the nozzle.

(1) Checking valve opening pressure

• Push down the lever of the nozzle tester at a rate of 1 to 2 sec-
onds per stroke. The pressure gauge reading will gradually rise,
then the needle will suddenly deflect. Read the gauge when the
deflection starts;
• If the gauge reading deviates from the standard value, disas-
semble and clean it, and adjust the pressure by changing the
shims.
• If the gauge reading still deviates after adjustment, replace the
injection nozzle assembly.

(2) Checking spray pattern

• Pump the lever of the nozzle tester at a rate of 1 to 2 seconds
per stroke and maintain a continuous spray.
A: Even spray from all five injection orifices (Good)
B: Even and symmetrical spray (Good)
C: Asymmetrical spray (No Good)
D: Branched spray (No Good)
E: Thin spray (No Good)
F: Irregular spray (No Good)

• If the injection nozzle assembly appears defective, disassemble

and clean it, then inspect it again. If the injection nozzle assem-
bly still appears defective, it must be replaced.
• Check that the nozzle does not dribble after injection.

WARNING
• Never touch the spray that comes out of the nozzle.

(3) Checking for oil leaks

• Maintain the nozzle pressure at a level 1960 kPa {20 kgf/cm2}
lower than the specified 1st valve opening pressure, and check
that there are no fuel drips from the end of the nozzle.
• If the injection nozzle assembly appears defective, disassemble
and clean it, then inspect it again. If the injection nozzle assem-
bly still appears defective, it must be replaced.

13A-26
 13A
Removal procedure
Removal: Injection nozzle assembly

CAUTION
• Handle the needle valve with clean hands. Before touching
its sliding part, soak fingertips with the kerosene.
• Never change the combination of the needle valve and noz-
zle among the cylinders.

Cleaning procedure
Cleaning: Injection nozzle
Wash the needle valve and nozzle in kerosene, then remove any
carbon deposits from them in the following manner using the .
• Remove carbon from the end of the needle valve using the
cleaning bar of the .

CAUTION
• Never use a wire brush or any hard metallic object for clean-
ing.

• Insert the cleaning needle of the in the injection orifice of

the nozzle and remove carbon from the orifice by rotating the
needle.
Cleaning needle diameter: φ 0.18 mm or less.

• Clean the seat of the nozzle using the cleaning scraper of the
.
• To remove baked carbon, use the FUSO Carbon Remover.

13A-27
INJECTION NOZZLE
Inspection procedure
Inspection: Injection nozzle
• Wash the needle valve and nozzle in kerosene, before assem-
bling them together.
• Pull out the needle valve by approximately 1/3 of its length, then
check that it slides down under its own weight. (Repeat this test
several times, turning the needle valve each time.)
• If the needle valve does not slide down under its own weight,
wash it and perform this test again. If the needle valve is still
faulty, replace it and the nozzle as a set.

CAUTION
• When the nozzle is to be replaced, use a Nozzle Service Kit
that contains a nozzle, needle valve, pin, lift piece and spac-
er.
• After replacing the nozzle, be sure to readjust the pre-lift
such that the valve opening pressure meets the specified
standard valve.

Adjustment procedure
Adjustment: Valve opening pressure of injection nozzle
While reassembling parts, make valve opening pressure adjust-
ments in the following sequence.

CAUTION
• Before starting adjustments, clean all parts in clean kero-
sene to remove all dirt and other foreign matters.
• Handle the needle valve with clean hands. Before touching
its sliding surface, soak your fingertips with kerosene.

Adjusting 1st valve opening pressure

Checking full lift of needle valve

Checking pre-lift

Adjusting 2nd valve opening pressure

Final inspection

13A-28
 13A
Adjusting 1st valve opening pressure
• Fit the parts onto the nozzle holder as shown in the illustration.

• Install the lift piece with its round recess facing toward the push
rod.

• Fit the onto the nozzle, then secure the nozzle to the noz-
zle holder using the . Hand tighten the retaining nut until it
does not go any further, then tighten it to a torque of 48 to 53
N·m {4.9 to 5.4 kgf·m}.

• Connect the nozzle holder to the nozzle tester.

• Pumping the lever of the nozzle tester, measure the 1st valve
opening pressure.

13A-29
INJECTION NOZZLE
• If the reading deviates from the standard value, disassemble the
nozzle holder and exchange the shim for another shim with ap-
propriate thickness.
Thicknesses of available shims (φ 6.2 mm in outside diame-
ter) for 1st valve opening pressure adjustment:
0.40, 0.50, 0.52, 0.54, 0.56, 0.58, 0.60 and 0.70 mm

Checking full lift of needle valve

The full lift of the needle valve is checked in order to determine
whether or not the seat of the nozzle is abnormally worn or the in-
jection nozzle assembly is in order.
• Fit the and onto the .

• Mount the nozzle holder on the with its nozzle facing down.
• Fit the onto the nozzle holder.

• Screw the onto the .

• Connect the to the .

13A-30
 13A
• Fit the onto the nozzle holder so that the contacts the
upper end of the spring seat, then tighten the to secure the
dial gauge in place.

CAUTION
• Fasten the in such a way that a stroke of approximate-
ly 2 mm can be measured.
• Do not overtighten the . The shaft of the could be
stiffened.

• Connect the nozzle holder to the nozzle tester, then reset the
to zero.
• Loosen the and operate the nozzle tester to bleed all air
out of the . Check for fuel leaks at the same time.

• Operate the nozzle tester to increase the pipe pressure up to

somewhere between 34.3 and 44.1 MPa {350 and 450 kgf/cm2}.
The needle valve will lift to the maximum level. Record the full lift
of the needle valve.
A: Needle valve full lift
NOTE
• This test is performed to determine if the seat of the nozzle
is abnormally worn.

13A-31
INJECTION NOZZLE
Checking pre-lift
• With the needle valve at its full lift, release the handle of the noz-
zle tester. The pipe pressure will lower with a concomitant drop
in the reading (needle valve lift).
A: Amount of needle valve full lift
B: Pre-lift level
C: Pre-lift measuring point
• Read the when the action of 2nd spring has ceased with
the lowering of the needle valve stopped (at pre-lift level B), to
determine if the reading (pre-lift) is within the specified limits.
• Read the with the needle valve at the pre-lift measuring
point (1st valve opening pressure + approximately 1 MPa {10
kgf/cm2}). (Observe the dial gauge while lowering the pressure.)

• If the reading is not within the specified limits, replace the

pin, lift piece, spacer, nozzle and needle valve with the corre-
sponding parts in a Nozzle Service Kit.
D: Capsule (BOSCH AUTOMOTIVE SYSTEMS part No.
105019-1300)

13A-32
 13A
Adjusting 2nd valve opening pressure
• After checking the pre-lift, operate the nozzle tester to increase
the pipe pressure up to somewhere between 34.3 and 44.1 MPa
{350 and 450 kgf/cm2} so that the needle valve fully lifts.
• Release the handle of the nozzle tester. The pipe pressure will
lower with a concomitant drop in the reading (needle valve
lift).

• Read the pressure gauge of the nozzle tester the moment the
indicates the specified amount of needle valve lift (normal
pre-lift + 0.05 mm).
A: Needle valve full lift.
E: Normal pre-lift
F: Pressure gauge

• If the gauge reading deviates from the specified limits, disas-

semble the nozzle holder and make pressure adjustment by ex-
changing the shim for another shim with appropriate thickness.
CAUTION
• Adjusting the 1st valve opening pressure changes the 2nd
valve opening pressure; therefore, after the 1st valve open-
ing pressure is altered be sure to check and adjust the 2nd
valve opening pressure.

Thicknesses of available shims (7.2 mm in outside diame-

ter) for 2nd valve opening pressure adjustment:
0.10, 0.20, 0.30, 0.40, 0.50, 0.51, 0.52, 0.53, 0.54, 0.55, 0.56,
0.57, 0.58 and 0.59 mm

13A-33
INJECTION NOZZLE
Final inspection
Upon completion of all necessary adjustments, perform final in-
spection on the injection nozzle assembly according to the follow-
ing procedure.
• Remove the , and .

• Remove the and .

• Check that the pin is secured in position. Install the retaining nut
handtight, then tighten it to the specified torque.
• Fit the nozzle holder onto the nozzle tester. Using the nozzle
tester, check the 1st valve opening pressure, spray form and oil
tightness of the nozzle seat. Check that all parts are leak-free at
the same time. (See Inspection: Injection nozzle.)

13A-34