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Fuel System
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FUEL SYSTEM
CHAPTER 4 FUEL SYSTEM
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
FUEL SYSTEM SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 DIESEL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 PRINCIPAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 PRIMING THE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 FUEL SYSTEM ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 FUEL PICK-UP / SENDING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 FUEL LINES / VENT LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 FUEL PICK-UP SCREEN SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 FUEL SENDER TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 FUEL PICK-UP / SENDING UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 FUEL TANK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10 FUEL TANK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
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SPECIAL TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 TEST AND ADJUSTMENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
FUEL TRANSFER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
FUEL FILTER / WATER SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
FUEL FILTER / WATER SEPARATOR DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16 FUEL FILTER / WATER SEPARATOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 4.16
FUEL INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
FUEL INJECTION LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20
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FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22
REMOVING THE FUEL INJECTION PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22 INSTALLING THE FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24 CHECKING FUEL INJECTION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.26 ADJUSTING FUEL INJECTION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.29 REMOVING THE FUEL INJECTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.31 TESTING THE FUEL INJECTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.32 FUEL INJECTOR TEST RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.33 DISASSEMBLING AND INSPECTING FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . 4.34 ADJUSTING FUEL INJECTOR PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.35 ASSEMBLING THE FUEL INJECTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.35 INSTALLING THE FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.35
CHECKING AND ADJUSTING FUEL INJECTION TIMING . . . . . . . . . . . . . . . . . . . . . . 4.26 FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.31
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REMOVING THE HIGH-PRESSURE INJECTION LINES . . . . . . . . . . . . . . . . . . . . . . . 4.20 INSTALLING THE HIGH-PRESSURE INJECTION LINES . . . . . . . . . . . . . . . . . . . . . . 4.20 REMOVING THE FUEL RETURN LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21 INSTALLING THE FUEL RETURN LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
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ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17 FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18 FUEL SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19
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OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14 FUEL PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14 FUEL PUMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
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FUEL TANK ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
FUEL SYSTEM
SAFETY PRECAUTIONS
Diesel Fuel System WARNING
Diesel fuel is flammable and explosive under certain conditions. Fuel injection components are under high pressure. Verify system pressure has been relieved before system disassembly. NEVER start the engine or let it run in an enclosed area. Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Before you operate the engine, check for fuel leaks. NEVER drain the fuel system when the engine is hot. Severe burns may result. When you prime the fuel system, turn the key switch to the ON position for 10 to 15 seconds to allow the electric fuel transfer pump to prime the fuel system. Only use the key switch to start the engine. NEVER jump-start the engine. Sparks caused by shorting the battery to the starter motor terminals may cause a fire or explosion.
FUEL SYSTEM SPECIFICATIONS
Special Torque Chart
Component Fuel Injector Fuel Pump Drive Gear Nut High-Pressure Fuel Injection Line Nuts Fuel Return Line Nuts Fuel Injection Pump Mounting Bolts Torque Value 36.1 - 39.1 ft-lbs (49 - 53 Nm)
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1784 - 1929 psi (12.3 - 13.3 MPa; 123 - 133 bar)
Fuel Injector Nozzle Case Nut
Test and Adjustment Specifications
Fuel Injector Pressure Fuel Injection Timing
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NOTE: Fuel injector pressures given are for used parts. New injectors (5 hours operation or less) will read approximately 72.5 psi (0.5 MPa; 5 bar) higher.
NEVER use diesel fuel as a cleaning agent. Always turn off the engine before refueling. Always refuel outdoors or in a well-ventilated area. Do not overfill the tank. The tank is at full capacity when the fuel reaches the bottom of the filler neck. Leave room for expansion.
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Do not smoke or allow open flames or sparks in or near the area where refueling is being performed or where fuel is stored.
If you get fuel in your eyes or if you should swallow fuel, seek medical attention immediately. If you spill on your skin or clothing, immediately wash it off with soap and water and change clothing.
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NEVER use a shop rag to catch diesel fuel. Vapors from the rag are flammable and explosive. Wipe up any fuel spills immediately.
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22 - 25 ft-lbs (29 - 34 Nm) 18 - 24 ft-lbs (24 - 33 Nm)
17 - 21 ft-lbs (23 - 28 Nm)
21.4 - 36.1 ft-lbs (29 - 49 Nm)
See "Checking and Adjusting Fuel Injection Timing"
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44 - 51 ft-lbs (59 - 69 Nm)
FUEL SYSTEM
GENERAL INFORMATION
Special Tools
Item A B C Part Number PU-50326 PU-50530 PU-50532 Tool Description PFA Nut Tool Diesel Injection Timing Tool Diesel Fuel Injector Tester
Diesel Service Notes
· NEVER attempt to service any fuel system component while engine is running or ignition switch is "on". · Cleanliness is essential and must be maintained at all times when servicing or working on the fuel system. Dirt, even in small quantities, can cause significant problems. · Do not use compressed air if the system is open. Cover any parts removed and wrap any open joints with plastic if they will remain open for any length of time. New parts should be removed from their protective packaging just prior to installation.
SPX Corp: 1-800-328-6657 or http://polaris.spx.com/
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battery while
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· Clean any connection before opening to prevent dirt from entering the system.
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· NEVER disconnect running.
· Although every precaution has been taken to prevent water intrusion failures, avoid high pressure spray contact with system components. · Do not allow the battery cables to touch opposing terminals. When connecting battery cables attach the positive (+) cable to positive (+) battery terminal first, followed by negative (-) cable to negative (-) battery terminal.
· NEVER start the engine when the cables are loose or poorly connected to the battery terminals. engine is
· Do not charge battery with key switch "on." · Always disconnect negative (-) battery cable lead before charging battery.
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IMPORTANT: The fuel system remains under pressure, even when the engine is not running. Before attempting to service any part of the fuel system, pressure must be relieved (if applicable).
4.3
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FUEL SYSTEM
Principal Components
The fuel system is a complete engine fuel management design. This system includes the following principal components: · Fuel Pump · Fuel Filter / Water Separator Assembly · Fuel Injection unit · The fuel system contains both high and low pressure systems (supply and injection)
Priming the Fuel System
NOTE: The injection system must be purged of all air prior to the initial start up, and / or any time the system has been disassembled. If the fuel system is completely empty or has been disassembled for repairs, perform the following:
Operation Overview
The fuel injection system is designed to provide peak engine performance with optimum fuel efficiency and lowest possible emissions. The injection functions are mechanically controlled and governed. NOTE: The fuel injection unit is not serviceable. It must be serviced by an authorized FIE repair facility. An in-line electric fuel pump is used to move fuel from the tank through the fuel line and in-line fuel filter/water separator. The fuel pump maintains a system operating pressure of 1-5 psi. Any excess fuel returns to the tank via the return line attached to the injection system.
2. Locate the air bleed screw on top of the fuel filter / water separator. Slowly open and close the bleed screw to remove any air trapped in the system.
At the engine, fuel is fed to the fuel injection control unit, which operates the injectors. A precise amount is injected into the pre-combustion chambers.
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3. Turn the key switch to "START" until the engine starts or 5 seconds has passed. 4. If the engine failed to start, repeat steps one and two. If the engine fails to start, a fuel supply problem may exist, and should be diagnosed.
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1. Turn the key switch to the ON position for 10-15 seconds.
FUEL SYSTEM
Fuel System Assembly View
2 11 1. Fuel Tank Assembly 2. Fuel Pick-Up / Sending Unit 3. Fuel Pump 4. Fuel Filter / Water Separator 5. Fuel Supply Line 6. Fuel Solenoid 7. Injection Unit 8. High Pressure Injection Lines 9. Fuel Injectors 10. Fuel Return Line 11. Vent Line
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8 7 Injection lines Fuel Injectors
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6 Bypass / Return Flow Fuel Pump Fuel Filter / Water Separator
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Fuel Flow
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Fuel Tank
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9 Fuel Injection Unit Fuel Solenoid
4.5
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FUEL SYSTEM
FUEL TANK ASSEMBLY
Fuel Pick-Up / Sending Unit
*See "Fuel Pick-Up / Sending Unit Removal" for service procedure. 1 1. PFA Nut* 2. Fuel Supply Fitting 3. Fuel Float Arm 4. Fuel Sending Unit 5. Fuel Pick-Up 6. PFA Gasket 7. Fuel Tank Assembly 8. Fuel Return Fitting 9. Tank Vent Fitting
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FUEL SYSTEM
Fuel Lines / Vent Line
1. Remove the drivers seat base and storage tray. Tilt the rear cargo box. 2. Check the fuel supply lines (Item 1) and return line (Item 2) at the fuel tank and fuel pump for signs of wear, deterioration, damage or leakage. Replace line(s) if necessary. 1 3 1 2
Fuel Pick-up Screen Service
The fuel pick-up screen (Item 1) is located in the fuel tank at the bottom of the fuel pick-up. The screen can be cleaned, but is not serviceable. If replacement is required, the entire fuel pick-up / sender assembly (Item 2) must be replaced (see "Fuel Pick-Up / Sending Unit Removal").
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2 3. Check the fuel tank vent line (Item 3) for signs of wear, deterioration, damage or leakage. Replace vent line every two years.
4. Check the fuel supply line (Item 4) and return line (Item 5) at the engine for signs of wear, deterioration, damage or leakage. Replace line(s) if necessary. 5
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5. Be sure fuel lines and vent line are routed and retained properly.
IMPORTANT: Make sure lines are not kinked or pinched.
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FUEL SYSTEM
Fuel Sender Tests
If the fuel gauge reading on the instrument cluster is not working, or if the display reading differs in large comparison to the amount of fuel in the tank, perform a resistance test on the fuel sender. 1. Remove the fuel sending unit assembly from the fuel tank (see "Fuel Pick-Up / Sending Unit Removal"). 2. Using an Ohm meter, measure the resistance of the fuel sender as shown below.
Fuel Pick-Up / Sending Unit Removal
1. Move the vehicle to a well ventilated area. Shift the transmission into Park and turn the ignition key off. 2. Remove the passenger seat base and storage tray to access the battery. 3. Disconnect the negative battery cable. 4. Remove the driver's seat base and storage tray to access the top of the fuel tank.
5. Thoroughly clean the top of the fuel tank before disassembly.
Fuel Sender - Empty: 6 ± 2
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3. Allow the sender float to sit in the empty position and compare to specification.
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6. Disconnect the fuel supply line (Item 1) from the fuel pick-up / sending unit (Item 2).
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Always wear safety goggles when working with flammable fluids. Failure to do so could result in serious injury or complications.
Failure to clean area around fuel pick-up / sending unit may lead to debris entering the fuel tank during service. Excessive debris in fuel tank may clog the fuel pick-up screen.
4. Slowly move the sender float to the full position and compare to specification.
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Fuel Sender - Full: 102 ± 2
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5. If the readings are out of specification, or if the reading is erratic or LCD display "sticks", check the following before replacing the fuel sending unit: · Loose float · Float contact with tank · Bent float rod NOTE: A small amount of fuel may come out of the fuel line. Properly drain fuel into a suitable container. 7. Disconnect the fuel sending unit harness (Item 3).
6. If none of the conditions exist, the fuel sending unit is faulty and requires replacement (see "Fuel Pick-Up / Sending Unit Removal").
4.8
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WARNING CAUTION
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FUEL SYSTEM
8. Place the Special Tool (PU-50326) over the fuel pickup / sending unit PFA nut (Item 4). Using a 1/2" drive ratchet or breaker bar, loosen and remove the PFA nut. Discard the PFA nut. IMPORTANT: If there is debris in the fuel tank, it is recommended to remove the fuel tank from the vehicle and rinse it with a small amount of clean fuel. Do not use water or any other chemicals to remove debris. 12. Remove new fuel pick-up / sending unit, gasket and PFA nut from packaging. Use care not to bend float arm during un-packaging. Do not lift or carry fuel pickup / sending unit by wire harness or the float arm
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14. Install new PFA gasket onto fuel pick-up / sending unit using care not to damage gasket or bend float arm.
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13. Use cleaning wipes provided to clean fuel tank surface and threads. Remove all debris, grease and oil. Allow surfaces to dry completely.
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Special Tool: PU-50326 9. Carefully lift the fuel pick-up / sending unit out of the fuel tank. During removal, be aware of the float arm (Item 5) and pick-up screen (Item 6). Hold the float arm in during removal to ensure that the float arm is not bent when removed from the tank.
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10. Discard the PFA gasket (Item 7).
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6 15. Install fuel pick-up / sending unit into fuel tank, hold float arm in to ensure float arm does not get caught or bent during installation.
11. Inspect the inside of the fuel tank for debris (may require flashlight and mirror). If debris like mud or sand is present, fuel tank should be flushed and cleaned out prior to installation of new fuel pick-up / sending unit.
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FUEL SYSTEM
16. Roughly align the fuel supply outlet between the orientation marks on fuel tank to ensure float arm does not get bent or snagged.
Fuel Tank Removal WARNING
Always wear safety goggles when working with high pressure or flammable fluids. Failure to do so could result in serious injury or complications. 1. Remove the passenger seat and storage tray. Disconnect the negative (-) battery cable. 2. Remove the driver's seat, disconnect the seat switch (if equipped) and remove the storage tray. 3. Disconnect the fuel lines (Item 1), vent hose (Item 2) and fuel sender harness (Item 3).
CAUTION
Failure to align with the orientation marks may lead to interferences with the fuel level float arm and cause incorrect function. 17. Thread the new PFA nut onto the fuel tank and hand tighten. Use care when starting PFA nut, ensuring threads are properly aligned. Verify the fuel supply outlet is still aligned between the fuel tank marks. 18. Hold down on fuel pick-up / sending unit to prevent from rotating. Use care when tightening PFA nut to avoid damaging wire harness lead. 19. Torque PFA nut to specification using the Special Tool (PU-50326) and a calibrated torque wrench.
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3 2 4 5. Remove the center console.
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20. Verify fuel supply outlet is aligned with fuel tank orientation marks. 21. Connect fuel supply line to fuel pick-up / sending unit. 22. Connect the fuel sending unit harness and connect the negative battery cable. 23. Install the driver and passenger seat bases and storage trays. 24. Test the fuel sending unit by turning on the ignition key and observing the gauge to indicate present fuel level.
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PFA Nut: 70 ± 5 ft-lbs (95 ± 7 Nm)
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NOTE: A small amount of fuel may come out of the fuel line. Plug the fuel line during removal. 4. Disconnect the harness (Item 4) from the 2-speed solenoid.
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FUEL SYSTEM
6. Remove the fasteners (Item 5) retaining the joystick to the seat base (HD / HDPTO models only). 12. Remove the two fasteners (Item 10) retaining the lower part of the seat base to the frame. 8
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7. Remove the two fasteners (Item 6) retaining the throttle lever to the seat base (HD / HDPTO models only). 8. Remove the floor (see Chapter 7 "Main Floor"). 9. Remove bolt (Item 7) retaining the hydraulic line restrain to the frame.
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10. Use a 13mm socket to remove the upper mounting bolt (Item 8) and a 10mm socket to remove the two lower mounting bolts (Item 9), retaining the A/C condenser to the frame. 11. Remove the two fasteners (Item 10) retaining the 2speed manifold to the seat base.
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15. Cut the three tie straps retaining the harness to the side of the tank (locations marked with white tape). IMPORTANT: Syphon as much fuel from the tank as possible before attempting to remove it. Drain the remaining fuel into a suitable container upon removal. NOTE: Tie the harness and hydraulic lines up and to the passenger side so they are out of the way upon tank removal and installation.
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13. Remove the two fasteners retaining the upper seat base to the frame (there may be two T-40 Torx screws retaining the block-off panel to the seat support). 14. Remove the two fuel tank strap fasteners (Item 12) and remove both straps.
FUEL SYSTEM
16. Remove the fuel tank by lifting the side towards the middle of the vehicle (fuel sender side). Make sure the fuel fill neck is clear of the A/C hoses running to the condenser (HDPTO models only). 4. Install the two fasteners retaining the upper seat base to the frame. Torque fasteners to specification.
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Upper/Lower Seat Base Fasteners: 14 ft-lbs (19 Nm) 5. Install the two fasteners retaining the lower part of the seat base to the frame. Torque fasteners (Item 2) to specification.
Fuel Tank Installation
1. Reinstall the fuel tank into the chassis taking care not to damage brake lines, hoses or the wire harness. 2. Install (3) plastic tie straps to retain the wire harness to the fuel tank (locations marked with white tape).
6. Install the two fasteners retaining the 2-speed manifold to the seat base. Torque fasteners (Item 3) to specification.
3. Install the fuel tank mounting straps and the two fasteners retaining fuel tank to chassis. Torque fasteners (Item 1) to specification.
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7. Position the A/C condenser on the frame. Use a 13mm socket to install the upper mounting bolt (Item 4) and a 10mm socket on the two lower mounting bolts (Item 5). Torque fasteners to specification. 4
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Fuel Tank Mounting Straps Fasteners: 8 ft-lbs (11 Nm)
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Upper/Lower Seat Base Fasteners: 14 ft-lbs (19 Nm)
2-Speed Manifold Mounting Fasteners: 8 ft-lbs (11 Nm)
A/C Condenser Upper Mounting Fastener: 14 ft-lbs (19 Nm)
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A/C Condenser Lower Mounting Fasteners: 8 ft-lbs (11 Nm) 8. Install the hydraulic line restrain and the retaining bolt. Torque the retaining bolt (Item 6) to specification. 11. Install the fasteners retaining the joystick to the seat base (HD / HDPTO models only). Torque the fasteners (Item 8) to specification.
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Hydraulic Joystick Mounting Bolts: 17 ft-lbs (23 Nm) 12. Install the center console.
13. Connect the harness (Item 9) to the 2-speed solenoid.
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Hydraulic Line Restrain Mounting Bolt: 8 ft-lbs (11 Nm)
9. Install the floor (see Chapter 7 "Main Floor").
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10. Install the two fasteners retaining the throttle lever to the seat base (HD / HDPTO models only). Torque the fasteners (Item 7) to specification.
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18. Install the passenger seat. Throttle Lever Mounting Fasteners: 15 ft-lbs (20 Nm)
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14. Connect the fuel lines (Item 10), vent hose (Item 11) and fuel sender harness (Item 12).
15. Connect the negative (-) battery cable. 16. Install the seat base storage trays. 17. Install the driver's seat and connect the seat switch (if equipped).
FUEL SYSTEM
FUEL TRANSFER PUMP
Operation Overview
The electric fuel transfer pump (Item 1) is used to supply fuel from the tank to the fuel injection system. The main inline components for fuel transfer include the fuel pump and fuel/water separator. The pump is rated for a 1-5 psi output. 1 2 1. Tilt the rear cargo box. Remove the fuel line from the fitting on top of the fuel filter/water separator (Item 2).
2. Install a commercially available low pressure test gauge on the fuel line between the fuel pump and the fuel filter / water separator. 3. Turn the key switch on and check the system pressure on the gauge. If system pressure of 1-5 psi is observed, the ignition switch and fuel pump are working properly. Turn the key switch off to relieve the system pressure. Fuel Transfer Pump Pressure: 1-5 psi
The fuel pump is activated any time the key switch is turned to the "ON" position.
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NOTE: The fuel transfer pump is non-serviceable and must be replaced if determined to be faulty. If a fuel delivery problem is suspected, make certain the fuel pump is being activated when the key switch is `ON', all electrical connections are properly secured, the fuses are good, and a minimum of 12.0 Vdc is being supplied.
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Fuel Pump Test
WARNING
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Fuel is extremely flammable and may cause severe burns, injury, or death. Do not use any device that produces a flame or electrical devices that may spark around fuel or fuel vapors.
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When the key switch is turned to "ON", 12Vdc power activates the fuel pump, which pressurizes the system for start-up.
NOTE: If the fuel pump did not operate, proceed to the next step. If the pump operated, but fuel pressure was too low, check the fuel pick-up screen (see "Fuel Pick-up Screen Service"). If the pick-up screen is ok and the pump still operates, replace the fuel pump. 4. If the pump does not operate, disconnect the plug from the fuel pump. Connect a DC voltmeter across terminals in the plug on the vehicle harness side. Turn on the key switch and observe voltage to ensure a minimum of 12 Vdc is present. NOTE: If the voltage was below 12 Vdc, test battery, ignition switch, relay(s), wiring harness and ECM. 5. If voltage at the plug is within the specified range, and there is continuity across the pump terminals, reconnect the plug to the fuel pump, making sure you have clean connections. Turn on the key switch and listen for the pump to activate. NOTE: If the pump operates, verify you have the correct amount of fuel pressure. If the pump still does not operate, replace the fuel pump (see "Fuel Pump Replacement").
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FUEL SYSTEM
Fuel Pump Replacement WARNING
Always wear safety goggles when working with high pressure or flammable fluids. Failure to do so could result in serious injury or complications. 1. Remove the driver's seat, disconnect the seat switch (if equipped). Remove the storage tray to access the fuel pump. 2. Disconnect the electrical harness (Item 3) from the fuel pump.
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4. Remove the bracket fasteners (Item 5) and remove the pump from the frame. 5. Install the new pump onto the frame and reinstall the bracket fasteners. Tighten fasteners securely.
7. Reconnect the electrical harness. 8. Turn the ignition key ON for 10-15 seconds and listen to be sure the pump operates. 9. Check for any fuel leaks. 10. Start engine and check for fuel leaks.
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6. Install the fuel lines and spring clamps securely.
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3. Place a suitable container under the fuel pump and remove the fuel line (Item 4) from each end of the fuel pump. Dispose of the fuel properly.
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FUEL SYSTEM
FUEL FILTER / WATER SEPARATOR
Fuel Filter / Water Separator Draining CAUTION
Both fuel and water will drain from the separator during the following procedure. Use caution and observe all fuel safety precautions when handling fuel. 1. Be sure engine is cool and the battery is disconnected. 2. Tilt the cargo box to access the fuel filter / water separator. 3. Place an approved container under the fuel filter / water separator (Item 1) to collect the contaminants. Locate the black drain valve at the bottom (Item 2). 5. Allow any contaminants to completely drain from the valve until clear fuel is visible. Firmly tighten or close the valve hand-tight only (small arrow). 6. Dispose of contaminants and excess fuel properly. 7. Reconnect the battery. 8. Turn key switch ON for 10-15 seconds to prime the fuel system. Doing so will force air out of the fuel system. NOTE: At times it may be necessary to open the bleed screw on the fuel filter housing until fuel comes from the valve with no air bubbles. 9. Start engine and verify that no fuel leaks are present.
Fuel Filter / Water Separator Replacement
1. Follow Steps 1-6 from the "Fuel Filter / Water Separator Draining" procedure. 2. Unscrew fuel filter / water separator from the filter mount using a commercially available filter wrench if it is not removable by hand. The filter has standard rotation threads. 3. Properly drain and dispose of fuel filter / water separator. 4. Lightly lubricate the rubber gasket of the new fuel filter / water separator with fresh engine oil. 5. Thread the new filter onto the filter mount until the gasket lightly touches the filter housing. Tighten filter 1/2-3/4 of a turn after initial contact of the rubber gasket to the filter mount. IMPORTANT: Be sure that the drain valve on the bottom of the filter is snug and did not loosen up during filter installation. 6. Clean up any excess fuel properly. 7. Reconnect the battery. 8. Turn key switch ON for 10-15 seconds to prime the fuel system. 9. Start engine and verify that no fuel leaks are present.
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4. Reach under the fuel filter / water separator and unscrew or open the black drain valve (large arrow) until fuel starts to drain out of the bottom of the valve (1/2 to 1 turn). Do not unscrew the drain valve completely.
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FUEL SYSTEM
FUEL INJECTION SYSTEM
Assembly View
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1. Fuel Return Line Nut 2. Fuel Return Line 3. High-Pressure Fuel Injection Lines 4. Low-Pressure Fuel Return Hose (A) 5. Fuel Return Fitting 6. Fuel Injector 7. Fuel Injection Pump
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8. Lock Washer 9. Fuel Injection Pump Drive Gear Nut 10. Fuel Injection Pump Drive Gear Assembly 11. Mechanical Fuel Pump Boss (Not Used) 12. Low-Pressure Fuel Inlet Fitting (B) 13. Fuel Filter / Water Separator 14. Fuel Feed Pump (Electric)
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FUEL SYSTEM
Fuel Injection Pump
IMPORTANT: Contact Polaris Technical Service for assistance to have the MC fuel injection pump serviced. · NEVER remove or attempt to remove the tamper proof devices from the full-load fuel adjusting screw or the high-speed throttle limit screw on the fuel injection pump and governor assembly. These adjustments have been made at the factory to meet all applicable emissions regulations and then sealed.
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· NEVER attempt to make any adjustments to these sealed adjustment screws. If adjustments are required, they can be made only by a qualified fuel injection shop that will ensure the injection pump continues to meet all applicable emissions regulations, and then replace the tamper-proof seals.
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· Tampering with or removing these devices may void the "Limited Warranty."
The following describes the features of the MC fuel injection pump, manufactured by Yanmar.
The fuel injection pump is a very important component of the engine. It is capable of making very precise fuel delivery adjustments according to the varied loads applied to the engine.
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NOTE: If the fuel injection pump itself requires servicing, it must be taken to an authorized Yanmar FIE (Fuel Injection Equipment) repair facility.
All of the fuel injection pump components are very precisely machined. It is extremely important to follow good service practices and maintain cleanliness when servicing the fuel injection pump. The Yanmar Fuel Injection Pump is an in-line type pump which consists of a fuel supply plunger (A) for each cylinder, a camshaft (B) and a pump housing (C). A delivery valve (D) connects to a high-pressure fuel line for each cylinder. The fuel injection pump housing contains a governor (E).
Fuel from the fuel tank to the fuel injection pump is delivered by a low-pressure electric fuel feed pump. On a few special models, a mechanical fuel feed pump is used instead of an electric pump. The mechanical fuel feed pump is mounted to the fuel injection pump housing in place of the cover plate (F). Fuel to be injected into the cylinders is pressurized by the up and down motion of each camshaft-driven plunger, and is then supplied by the high-pressure fuel lines to the respective fuel injector. The fuel injector is essentially a spring-loaded valve. When fuel pressure from the fuel injection pump reaches a pre-determined level, the pintle (valve) is forced off its seat and fuel is atomized as it passes between the pintle and seat. The timing and quantity of the fuel injected into the cylinder is controlled by the fuel injection pump and governor assembly.
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FUEL SYSTEM
Fuel Solenoid
The fuel injection pump is equipped with a fuel solenoid that controls the fuel flow inside the fuel injection pump. With the starter switch in the OFF position, no current flows to the fuel solenoid and the solenoid plunger is extended, holding the fuel injection pump fuel rack in the "closed" position and not allowing fuel to flow through the injection pump and to the engine. When the starter switch is turned to the start position, the "pull coil" (36.5-amp draw / white wire) inside the solenoid is activated and pulls the solenoid plunger into the solenoid. This releases the fuel injection pump fuel rack, allowing fuel to flow through the injection pump and allowing the engine to start and run. When the starter switch is returned to the ON or RUN position, the "pull coil" no longer receives current and the "hold coil" (0.5-amp draw / red wire) inside the solenoid is activated. The "hold coil" holds the solenoid plunger in the RUN position, allowing fuel to continue flowing and the engine to continue running. To stop the engine, the key switch is turned to the OFF position. Current no longer flows to the fuel solenoid "hold coil," and the solenoid plunger extends and moves the injection pump fuel rack to the "closed" position, shutting off the fuel flow and stopping the engine.
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Failure of the fuel solenoid could result in the engine not starting, the engine stopping suddenly, the engine continuing to run with the key switch returned to the ON or RUN position or the engine failing to stop when the key switch is turned to the OFF position. Use a VOA multimeter or continuity light to check for a good ground and 12V at the fuel solenoid in the correct sequence.
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FUEL SYSTEM
FUEL INJECTION LINES
Removing the High-Pressure Injection Lines
IMPORTANT: Remove and install the high-pressure fuel injection lines as an assembly whenever possible. Disassembling the high-pressure fuel injection lines from the retainers or bending any of the fuel lines will make it difficult to install the fuel lines. NOTE: To prevent "rounding" the fuel line nuts, always use a "line" or "flare nut" wrench. 1. Close any fuel valves in the fuel supply line. 2. Clean the area to keep contaminants from entering the fuel system. 3. Place a drain pan under the fuel injection pump to catch any spillage. 4. Loosen the fuel line nuts at the fuel injection pump. 5. Next, loosen the fuel line nuts at the fuel injectors. Use one wrench to hold the fuel return line nut and fuel return line from rotating. Use a second wrench to loosen the fuel line nut. Repeat with the remaining fuel injectors.
Installing the High-Pressure Injection Lines
IMPORTANT: Remove and install the high-pressure fuel injection lines as an assembly whenever possible. Disassembling the high-pressure fuel injection lines from the retainers or bending any of the fuel lines will make it difficult to install the fuel lines.
2. Tighten the fuel line nuts on the fuel injection pump to the specified torque (see "Special Torque Chart").
PR
6. Finish loosening all the fuel line nuts and remove the high-pressure fuel lines as an assembly, being careful not to bend any of the fuel lines. Be sure to protect the fuel system from contamination by plugging or covering all open connections.
7. Plug or cap all openings to minimize leakage and prevent contamination.
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3. When tightening the fuel line nuts on the fuel injectors, use one wrench to hold the fuel return line nut and fuel return line from rotating. Use a second wrench to tighten the fuel line nuts (see "Special Torque Chart).
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1. Start all the fuel line nuts by hand. Then use a wrench to "snug" all the fuel line nuts.
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NOTE: To prevent "rounding" the fuel line nuts, always use a "line" or "flare nut" wrench.
FUEL SYSTEM
Removing the Fuel Return Line
IMPORTANT: The fuel return line is a one-piece assembly. Use care not to bend or twist the fuel return line. 1. Clean the area to keep contaminants from entering the fuel system. 2. Remove the high-pressure fuel injection lines as an assembly (see "Removing the High-Pressure Injection Lines"). 3. Remove all fuel return line nuts (B) from the injectors (D).
Installing the Fuel Return Line
IMPORTANT: The fuel return line is a one-piece assembly. Use care not to bend or twist the fuel return line. 1. Install a new copper gasket on each fuel injector. 2. Carefully install the fuel return line assembly. 3. Install and hand-tighten the fuel return line nuts. 4. Tighten the fuel return line nuts to the specified torque (see "Special Torque Chart"). 5. Install the fuel return hose.
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5. Carefully remove the fuel return line assembly (C). 6. Remove and discard the copper gasket (A) from each fuel injector. 7. Plug or cap all openings to minimize leakage and prevent contamination.
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4. Remove the fuel return hose from the fuel return fitting on the fuel injection pump.
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6. Install the high-pressure fuel injection line assembly (see "Installing the High-Pressure Injection Lines").
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FUEL SYSTEM
FUEL INJECTION PUMP
Removing the Fuel Injection Pump WARNING
6. Disconnect the fuel return lines from the fitting on the fuel injection pump (D). Plug the open ends of the lines to minimize leakage and prevent contamination.
NEVER use diesel fuel as a cleaning agent. Always wear eye protection. The fuel system is under pressure and fuel could spray out when you remove any fuel system component. 1. Loosen the cooling pump V-belt (A) by loosening the alternator.
IN
2. Remove the engine belt guard, engine cooling pulley bolts (B), V-pulley (C) and V-belt.
PR
3. Place a drain pan under the fuel injection pump to catch any spillage. 4. Clean the area to keep contaminants from entering the fuel system. 5. Remove the high-pressure fuel injection lines as an assembly (see "Removing the High-Pressure Injection Lines").
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7. Remove the fuel supply line (E) from the fitting on the fuel injection pump. 8. Plug or cap all openings to minimize leakage and prevent contamination. 9. Remove the throttle cable from the fuel injection pump. 10. Disconnect the fuel solenoid wiring connector (F). 11. Remove the fuel injection pump drive gear access cover (G) from the gear case cover (H).
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NEVER use a shop rag to catch diesel fuel. Vapors from the rag are flammable and explosive. Wipe up any fuel spills immediately.
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When you remove any fuel system component to perform maintenance (such as changing the fuel filter), put an approved container under the opening to catch the fuel.
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Diesel fuel is flammable and explosive under certain conditions.
FUEL SYSTEM
NOTE: The cover is secured with an adhesive sealant. Use a gasket scraper to separate the cover from the gear case cover. 12. To aid in assembly, make alignment marks (J) on the pump drive gear and idler gear. 15. Remove the injection pump drive gear and hub from the injection pump drive shaft as an assembly using an appropriate gear puller.
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IMPORTANT: Mark the gears with something that will not rub off or be affected by oil and become illegible. If the gears are not marked or are illegible during installation, the gear case cover must be removed to properly time the injection pump gear. IMPORTANT: After marking the position of the pump drive gear, do not rotate the engine crankshaft. Rotating the crankshaft will cause the fuel injection pump to become misaligned. 13. Hold the gear train stationary using a wrench on the crankshaft pulley bolt. Remove the fuel injection pump drive gear retaining nut and washer (K).
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14. Thread the drive gear nut onto the injection pump shaft until it is even with the end of the shaft. This will prevent the gear from falling off of the shaft when using the puller.
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IMPORTANT: Do not loosen or remove the four bolts retaining the fuel injection pump drive gear to the fuel injection pump hub. Do not disassemble the fuel injection pump drive gear from the hub.
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16. Once the fuel injection pump drive gear and hub assembly have "popped" loose from the tapered fuel injection pump drive shaft, carefully remove the drive gear nut (L) and remove gear and hub assembly.
17. Remove the four bolts (M) and metal gasket (N) fastening the fuel injection pump to the cylinder block. Remove the fuel injection pump.
IMPORTANT: Do not rotate the crankshaft with the injection pump removed.
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FUEL SYSTEM
18. If the fuel injection pump requires servicing, it must be sent to an authorized Yanmar FIE repair facility for repair and calibration, or replaced with a new fuel injection pump. IMPORTANT: Contact Polaris Technical Service to have the MC fuel injection pump serviced. · NEVER remove or attempt to remove the tamper proof devices from the full-load fuel adjusting screw or the high-speed throttle limit screw on the fuel injection pump and governor assembly. These adjustments have been made at the factory to meet all applicable emissions regulations and then sealed. · NEVER attempt to make any adjustments to these sealed adjustment screws. If adjustments are required, they can be made only by a qualified fuel injection shop that will ensure the injection pump continues to meet all applicable emissions regulations, and then replace the tamper-proof seals. · Tampering with or removing these devices may void the "Limited Warranty."
Installing the Fuel Injection Pump
1. Install a new gasket to the mounting surface of the injection pump. 2. Install pump to the engine block using the four bolts (P) and metal gasket (Q). Tighten to the specified torque.
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NOTE: Ensure the tapered surface of the fuel injection pump shaft is clean and dry. 3. Align the key on the fuel injection pump shaft with the keyway in the fuel injection pump drive gear hub. Ensure the fuel injection pump drive gear is aligned with the idler gear using the reference marks made earlier (R).
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4. If installing the fuel injection pump on an engine with the front gear case cover removed, the fuel injection pump drive gear can be aligned with the idler gear by aligning the stamped marks (A, B, C) on the fuel injection pump drive gear, idler gear, camshaft gear and crankshaft drive gear. Ensure all three timing marks (A, B, C) are aligned. 6. Connect the fuel supply and return lines to the fuel injection pump. 7. Connect the throttle linkage and fuel solenoid wire connector. 8. If installing a new or recalibrated fuel injection pump, check the fuel injection timing before completing the installation of the fuel injection pump (see "Checking and Adjusting Fuel Injection Timing").
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5. Install the fuel injection pump drive gear lock washer (S) and nut (T). Do not lubricate threads of the nut or shaft. Hold the crankshaft pulley bolt with a wrench and tighten the pump drive gear nut to the specified torque (see "Special Torque Chart").
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9924344 - 2013 BRUTUS / HD / HDPTO Service Manual © Copyright 2013 Polaris Sales Inc.
9. After adjusting the fuel injection timing, apply ThreeBond Liquid Gasket No. 1212, or equivalent sealant to the sealing surface of the fuel injection pump drive gear access cover. Install the cover on the front of the gear case and tighten the bolts. 10. Install the fuel injection high-pressure lines (see "Installing the High-Pressure Injection Lines"). IMPORTANT: When installing a new or repaired fuel injection pump, it is important to add engine oil to the fuel injection pump to provide lubrication for initial start-up. Add 5 to 7 oz (150 to 200 cc) of clean engine oil to the fuel injection pump at the fill plug (U) located in the upper outside section of the governor housing.
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NOTE: While it is not required to check the injection timing when installing the original fuel injection pump, it is recommended that it be done.
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FUEL SYSTEM
11. Install the coolant pump V-pulley (V), pulley bolts (W) and V-belt (X).
CHECKING AND ADJUSTING FUEL INJECTION TIMING
Checking Fuel Injection Timing
NOTE: The following procedure is performed on the No. 1 cylinder. While checking and adjusting the timing on only No. 1 cylinder is usually sufficient, the same procedure can be performed on any or all cylinders.
WARNING
12. After installing the V-belt (X), adjust as described in "Checking and Adjusting Cooling Pump V-Belt". 13. Install the engine belt guard. 14. Prime the fuel system (see "Priming the Fuel System"). 15. Operate the engine and check for fuel and lube oil leaks.
NEVER use a shop rag to catch diesel fuel. Vapors from the rag are flammable and explosive. Wipe up any fuel spills immediately. 1. Ensure the fuel injection pump is primed with fuel (see "Priming the Fuel System"). 2. Clean the area around the fuel injection pump. IMPORTANT: Clean the area around the fuel injection pump to prevent any contamination when the fuel injection pump plunger plug is removed. NOTE: The fuel solenoid must be removed to allow fuel to flow through the fuel injection pump. 3. Remove the two screws (A).
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Use an approved container to catch fuel.
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Some fuel may drain from the fuel injection pump during this process. Use an approved container to catch fuel.
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4. Remove the fuel solenoid (B) and O-ring (C). 5. Set the throttle to the HIGH-IDLE position. 6. Remove the flywheel inspection port plug (D) to view the flywheel markings. NOTE: The TDC (Top Dead Center) mark can be identified by the cylinder numbers stamped near the TDC mark (5) on the flywheel. 8. If you are uncertain as to the timing degree designation of the timing marks on the flywheel timing grid, you can determine the timing degree designation by measuring the timing grid. · First measure the distance between two of the "longer" marks on the timing grid. (They are 5° apart.) Then measure the distance from the TDC mark to the first "longer" mark on the timing grid. Divide that measurement by the distance between the two "longer" marks. The resulting answer will tell you how many degrees there are between the TDC mark and the first "longer" mark.
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NOTE: The flywheel has a timing grid for each cylinder. Any grid and its corresponding cylinder can be used to check the fuel injection timing.
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7. Using a wrench on the crankshaft pulley bolt, rotate the crankshaft in a clockwise direction while looking through the flywheel inspection port. Rotate the crankshaft until the injection timing marks on the flywheel are visible for No. 1 cylinder.
· EXAMPLE: If the distance between the two "longer" marks is approximately 2.0 cm and the distance from the TDC mark is approximately 4.0 cm, the answer is approximately 2. This indicates there is 10° (2 x 5°) between the TDC mark and the first "longer" mark on the timing grid. That means the first "longer" mark on the timing grid indicates 10° BTDC, the second "longer" mark indicates 15° BTDC and the third timing mark indicates 20°. If the answer is 3, that indicates there is 15° (3 x 15°) between the TDC mark and the first "longer" mark and that the first "longer" mark indicates 15° BTDC with the second and third "longer" marks indicating 20° BTDC and 25° BTDC respectively.
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FUEL SYSTEM
9. Highlight the timing reference mark on the flywheel housing (E) or engine back plate (F). Highlight the TDC mark (G) on the flywheel. 11. Remove all high-pressure fuel injection lines (see "Removing the High-Pressure Injection Lines"). NOTE: As the injection pump injects fuel to a cylinder only once every two engine revolutions, it may be necessary to rotate the crankshaft twice to see fuel being pumped from the timing tool or delivery valve of the cylinder you are using to check injection timing. 12. Install the "spill-timing" tool (K) onto the delivery valve for the cylinder being checked (see "Special Tools").
IN
10. Highlight the target timing mark (H) on the flywheel timing grid as the injection timing measured before the fuel injection pump removal.
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Injection Timing (FID) VH RPM (min-1) 3TNM72 3600 20.0
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NOTE: If a timing tool is not available, timing can be checked by watching the fuel in the delivery valve itself. NOTE: The following references to the direction of rotation are made facing the cooling pump end of the engine and are adjusted by turning the crankshaft. 13. Slowly rotate the crankshaft clockwise using a wrench on the crankshaft pulley bolt until fuel is pumped from the nozzle of the "spill-timing" tool or delivery valve. 14. Slowly rotate the crankshaft clockwise approximately two more revolutions until the timing grid on the flywheel (for the cylinder being checked) is at approximately 30° BTDC. NOTE: The fuel injection pump injects fuel to a cylinder only once every two engine revolutions.
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15. "Flick" the nozzle of the timing tool with a finger to remove bubbles and establish a fuel level of approximately half the height of the nozzle. 16. Very slowly rotate the crankshaft clockwise until the fuel level in the nozzle of the "spill-timing" tool, or in the delivery valve, just begins to move. Immediately stop rotating the crankshaft. 17. Check the position of the flywheel target timing mark (H) on the flywheel grid in relation to the timing reference mark (J) on the flywheel housing or back plate. If the two marks are aligned, the fuel injection timing is correct. If the marks do not align, the fuel injection timing must be adjusted (see "Adjusting Fuel Injection Timing"). 18. Repeat Steps 13-17 two or three times to verify timing. 19. Remove the "spill-timing" tool. 20. Install the fuel solenoid. 21. Install the high-pressure fuel injection lines (see "Installing the High-Pressure Injection Lines"). 22. Install the flywheel inspection port plug.
Adjusting Fuel Injection Timing
If the timing marks did not align when performing the "Checking Fuel Injection Timing", the following steps must be performed to properly time the engine. The fuel injection pump of TNM engines is fixed with four bolts. Adjust the injection timing by rotating the pump drive gear on the pump flange. 1. Leave the "spill-timing" tool installed in the fuel injection pump. 2. Determine if the timing is "advanced" or "retarded" by comparing the position of the target timing mark on the flywheel grid (A) with the timing mark on the flywheel housing or back plate (B).
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23. Prime the fuel system. Operate the engine and check for leaks.
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3. The new injection pump will come with a timing grid sticker. Each line on the timing grid sticker is 1°. Each line on the flywheel grid is also 1°. 4. Observe the flywheel grid again and determine how many degrees you need to advance or retard the timing.
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FUEL SYSTEM
5. Clean the area of the gear by the pointer on the timing cover and put the sticker on the drive gear, aligning the timing mark on the timing cover (C) with the center of the sticker. 14. Install the high-pressure fuel injection lines (see "Installing the High-Pressure Injection Lines"). 15. Apply ThreeBond Liquid Gasket No. 1212 or equivalent sealant to the sealing surface of the fuel injection pump drive gear access cover. Install the cover on the front of the gear case and tighten the bolts. 16. Install the flywheel inspection port plug.
7. If the injection timing was less than the target timing, the injection timing is "retarded" and will need to be "advanced."
9. Tighten the pump drive gear mounting bolts.
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10. Recheck the fuel injection timing. Repeat the fuel injection timing and adjustment procedures until the timing is correct. 11. Remove the sticker from the pump drive gear. 12. Remove the "spill-timing" tool. 13. Install the fuel solenoid.
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8. Slowly rotate the crankshaft while watching the pointer on the timing cover and the timing grid sticker on the injection pump gear. Turn it the required number of degrees that was determined earlier when observing the flywheel grid.
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· To "retard" the injection timing: Rotate the crankshaft clockwise.
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· To "advance" the injection timing: Rotate the crankshaft counterclockwise. If the injection timing was greater than the target timing, the injection timing is "advanced" and will need to be "retarded."
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6. Loosen the four bolts (D) fastening the injection pump drive gear to the flange.
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17. Prime the fuel system. Operate the engine and check for leaks.
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FUEL INJECTORS
Removing the Fuel Injectors WARNING
5. Remove the nut (A). Remove the fuel return line (B) and copper washer (C) from the fuel injectors (see "Removing the Fuel Return Line").
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6. Remove the fuel injectors (D). 7. Remove the injector nozzle gaskets (E) and protector (F) from the cylinder head.
When you remove any fuel system component to perform maintenance (such as changing the fuel filter), put an approved container under the opening to catch the fuel. NEVER use a shop rag to catch diesel fuel. Vapors from the rag are flammable and explosive. Wipe up any fuel spills immediately. NEVER use diesel fuel as a cleaning agent. Always wear eye protection. The fuel system is under pressure and fuel could spray out when you remove any fuel system component. 1. Close any fuel valves in the fuel supply line.
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Diesel fuel is flammable and explosive under certain conditions.
2. Clean the area around the fuel injection pump and fuel injectors to keep contaminants from entering the engine or fuel system.
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4. Remove the high-pressure fuel injection lines as an assembly (see "Removing the High-Pressure Injection Lines").
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3. Remove the intake manifold / valve cover assembly (see "Removing the Intake Manifold / Valve Cover" in the Engine Chapter).
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FUEL SYSTEM
Testing the Fuel Injectors
IMPORTANT: Never use a steel wire brush to clean fuel injectors. Damage to the nozzle and other components is likely to result. 1. Thoroughly clean the fuel injector nozzle using clean diesel fuel and a brass wire brush. 2. Visually inspect the fuel injectors and nozzle protectors for deposits or damage. Clean, repair or replace as necessary. NOTE: Test the fuel injector using an injection nozzle tester. Operate the tester following the information provided by the tester manufacturer. Use clean, filtered fuel or FIE calibration fluid for the test. 3. Using the correct adapter, connect a fuel injector to a nozzle tester. Aim the fuel injector into a suitable container to catch the fuel spray. NOTE: Opening pressure of a new fuel injector will be approximately 72.5 psi (0.5 MPa; 5 bar) higher than one that has been operated for 5 hours or longer. 5. Pump the operating lever slowly to hold the pressure steady at a point just below the opening pressure and hold that pressure for 5 seconds. Observe the injector to see that it is sealing properly and is not "dripping." If fuel leaks from the return line fitting, check that the nozzle case nut is tight. Service or replace the injector if fuel continues to leak from either the return line fitting or nozzle. 6. Pump the operating lever more rapidly to repeatedly "pop" the injector and observe the spray pattern. The pattern should be a very fine uniform spray. If dripping or an uneven pattern is seen, service or replace the injector (see "Fuel Injector Test Results").
NEVER inject fuel toward a fire source. Atomized fuel is highly flammable and may cause a fire or burn skin.
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ALWAYS wear eye protection when servicing the engine and when using compressed air or highpressure water. Dust, flying debris, compressed air, pressurized water or steam may injure your eyes.
4. Pump the operating lever of the tester slowly, observing the pressure reading at the point where the fuel injector begins spraying fuel (see "Test and Adjustment Specifications" at the beginning of this Chapter for correct pressure readings).
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NEVER inject fuel toward you. Since the fuel is injected at high pressure from the nozzle, it may penetrate the skin, resulting in injury.
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FUEL SYSTEM
Fuel Injector Test Results
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NOTE: If the fuel injector fails any tests, it should be serviced or replaced as necessary. If the pressure is outside specified limits, adjust the pressure (see "Adjusting Fuel Injector Pressure").
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FUEL SYSTEM
Disassembling and Inspecting Fuel Injectors
IMPORTANT: Never use a steel wire brush to clean fuel injectors. Damage to the nozzle and other components is likely to result. 1. Clean carbon from used injectors using clean diesel fuel. Hardened deposits or varnish can be cleaned using a brass wire brush. 2. Place the fuel injector in a soft-jawed vise with the nozzle pointing up. 3. Remove the nozzle case nut. 4. Carefully remove the injector from the vise. 5. Turn the injector over and remove the nozzle body, nozzle valve, valve stop spacer, nozzle spring seat, nozzle spring and shims.
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7. Perform a nozzle valve slide test: · Wash nozzle body and valve in clean diesel fuel. · While holding the nozzle body vertical, pull the nozzle valve about 2/3 of the way out. · Release the valve. It should fall smoothly to its seat by its own weight.
NOTE: Replace the fuel injector assembly if it fails any inspection or if an injector tester is not available.
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6. Inspect the sealing surfaces (A) between the valve stop spacer and nozzle body for nicks or scratches. Check the contact area between the valve stop spacer and the nozzle valve (B) for scoring or pitting. Use a magnifying glass to inspect.
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FUEL SYSTEM
Adjusting Fuel Injector Pressure
The fuel injectors open when pressure reaches a predetermined pressure threshold. They close when the pressure is reduced below that threshold. The pressure threshold can be adjusted by adding or removing shims. Fuel Injector Shim Kit (PN 3070291) The injection pressure will change by approximately 100 to 142 psi (0.69 to 0.98 MPa; 6.9 to 9.8 bar) for every 0.004 in. (0.1 mm) shim thickness. See the Electronic Parts Catalog for available shims. 1. Disassemble the fuel injector assembly (see "Disassembling and Inspecting Fuel Injectors"). 2. Remove or add adjusting shims as needed. 3. Assemble the fuel injector "Assembling the Fuel Injectors"). assembly (see
Installing the Fuel Injectors
1. Insert the nozzle gaskets (E) and nozzle protector (F) in the cylinder head.
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2. Install the fuel injector (D) in the cylinder head and tighten to specification. 3. Install new copper washers (C) and high-pressure and return fuel lines (B) (see "Installing the HighPressure Injection Lines" and "Installing the Fuel Return Line"). Tighten fuel line nuts (A) to specification. 4. Install the intake manifold / valve cover (see "Assembling the Intake Manifold / Valve Cover" in Chapter 3). 5. Prime the fuel system (see "Priming the Fuel System"). 6. Operate the engine and check for fuel leaks.
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Assembling the Fuel Injectors
1. Secure the injector in a soft-jawed vise with the nozzle end up.
3. Install the nozzle case nut. Tighten it to specification.
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2. Install the shims, nozzle spring, nozzle spring seat, valve stop spacer, nozzle valve and nozzle body.
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4. Test the fuel injector (see "Testing the Fuel Injectors"). If the injector cannot be adjusted to the appropriate pressure, discard the fuel injector.
FUEL SYSTEM
NOTES
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