INJECTION PUMP TEST SPECIFICATIONS 196000-1980

196000- 198# MANU-

INJECTION PUMP (VE 4/12F2100RND198) TOYOTA
FACTURER

ENGINE
Governor Type Maximum-minimum speed 1KZ-T
TYPE

VEHICLE
Rated Voltage 12V 4RUNNER / HILUX
MODEL

Rotation Clockwise viewed from drive side Dimension (mm) MS : 0.15 – 0.25

Injection Order A–B–C–D Dimension (mm) K : 3.2 – 3.4

Injection Interval 90° ± 30' Dimension (mm) KF : 6.3 – 6.5

1. TEST CONDITIONS

1) Nozzle : 093400-0540 4) Feed Pressure : 0.2 kgf/cm 2

(DN12SD12A)

2) Nozzle Opening :145 – 155 kgf/cm 2 5) High Pressure Pipe : ø2 x ø6 x 840 mm

Pressure

3) Test Oil : SAE J967 (ISO4113) 6) Fuel Temperature : 40 – 45°C

(104 – 113°F)

NOTE: Apply 6 volts DC across the fuel cut solenoid during adjustment.

2. PRE-ADJUSTMENT (at full lever position, boost pressure 870 mmHg)

Fuel Delivery
Pump Speed (rpm) Remarks
(cc/200st ,cyl.)

Full Load 1800 14.4 – 15.0 By full load setting screw

High Speed 2300 5.1 – 7.3 By max. speed setting screw

Adjust the governor shaft so that the dimension "L" between the housing flange and the end of the
governor shaft is about 0.5 – 2.0 mm.

3. ADJUSTMENT OF PUMP INTERNAL PRESSURE (at full lever position, boost pressure 870 mmHg)

Pump Speed (rpm) Internal Pressure (kgf/cm 2) Remarks

500 4.2 – 4.8 By the regulating valve
2000 8.0 – 8.8

4. OVERFLOW QUANTITY CHECK (at full lever position, boost pressure 870 mmHg)

Pump Speed (rpm) Overflow Quantity (cc/100st) Remarks

The overflow valve belonging to the pump should

500 143 – 230
be used for checking.

5. ADJUSTMENT OF TIMER (at full lever position, boost pressure 870 mmHg)

Pump Speed (rpm) 600 1000 1500 2000

Piston Travel (mm) 0.7 – 1.5 3.9 – 4.7 6.6 – 7.4 8.56 – 9.04

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

 196000-1980
6. ADJUSTMENT OF FUEL DELIVERY

Lever Pump speed Fuel Delivery Max. Spread Boost

Position (rpm) (cc/200st,cyl) In Delivery Pressure Remarks
(cc) (mmHg)
FULL 1800 14.6 – 14.8 0.7 870 By full load setting screw
2300 5.3 – 7.1 — 870 By max. speed setting screw
2200 7.7 – 12.3 — 870
2450 Less than 3.0 — 870
100 14.7 – 19.3 1.3 370 By governor sleeve plug
1200 16.4 – 17.4 0.7 870

7. SETTING OF LOAD SENSING TIMER (at full lever position, boost pressure 400 mmHg) N.A. : Not Applicable
Pump Speed Fuel Delivery (cc/200st,cyl) Remarks
(rpm)

Start of Load Sensing 1000 Full-load delivery – ( 0.2 – 1.0 ) By governor shaft

End of Pressure Drop 1000 10.2 – 10.6 Check

CHECK POINTS 1. Piston Trevel at End of Pressure Drop : 1.85 – 2.65 mm (pump speed 1000 rpm)
2. Dimension of Governor Shaft : L = 0.5 – 2.0 mm

8. SETTING OF ADJUSTING LEVER AT LOW SPEED (at idle lever position, boost pressure 370 mm Hg )

Lever Pump Speed Fuel Delivery Max. Spread

Position (rpm) (cc/500st,cyl) In Delivery Remarks
(cc)
IDLE 350 A = 9.75 – 11.25 — Presetting
425 A – (7.0 to 9.5 ) —
1000 B = 4.5 – 5.0 — Dash pot OFF
1000 B + ( 0.15 to 0.4 ) — Dash pot adjustment
350 7.75 – 9.75 1.25 Lever setting

NOTE : Do the adjustment in the order from above.

9. ADJUSTMENT OF BOOST COMPENSATOR N.A. : Not Applicable

Pump Speed Boost Pressure Fuel Delivery Remarks
(rpm) (mmHg) (cc/200st,cyl)
500 0 8.2 – 9.2 By eccentric cam
500 485 12.3 – 12.9 By boost compensator spring
700 575 13.9 – 14.9 By boost compensator spring
1800 1020 14.5 – 14.9 OLP not operated
1800 1310 Less than 13.0 OLP operated

10. ADJUSTMENT OF T.C.V. N.A. : Not Applicable

Pump Speed Boost Pressure Piston Stroke
(rpm) (mmHg) (mm)

N.A. N.A. N.A.

INJECTION PUMP TEST SPECIFICATIONS 196000-1980
11. ADJUSTMENT OF THROTTLE POSITION SENSOR. 　　　　　　　　　　　　　　　　 N.A.: Not Applicable
Pump Speed (rpm) Condition Sensor Output Voltage
Set point N.A. N.A. N.A.
Check point N.A. N.A. N.A.

12. CHARACTERISTIC OF A.C.S.D. N.A. : Not Applicable

Lever Pump Speed Fuel Temperature
Measuring Value Remarks
Position (rpm) (°C)
IDLE N.A. N.A. N.A.
N.A. N.A. N.A.

13. ADJUSTMENT OF POWER CONTROL N.A. : Not Applicable

Boost
Lever Pump Speed Fuel Delivery
Pressure Remarks
Position (rpm) (cc/200st,cyl)
(mmHg)
FULL N.A. N.A. N.A.

14. SETTING OF DIAPHRAGM FOR HEATER

N.A.: Not Applicable
Boost Pressure
Lever Pump Speed Fuel Delivery
To Diaphragm Remarks
Position (rpm) (cc/200st ,cyl.)
(mmHg)
IDLE N.A. N.A. N.A.

15. FINAL CHECK AFTER ADJUSTMENT

(1) Range of lever angle is to between idle and full lever position is 46゜±5 ゜
(2) Resistance of pick-up tachometer must be 650 – 970 ohms.