101602-7570 ZEXEL 9 400 614 905 BOSCH INJECTION-PUMP ASSEMBLY 9400614905 1016027570 1156028530

Preparation for Inspection
Perform the following checks prior to inspection.(1) Make sure the engine oil, air cleaner, starter and battery are normal.(2) Make sure the engine is warm.Inspection
(1) Move the control lever to the top position.(2) Remove all glow plugs, then connect Compression Gauge Adapter (ST333060) and compression gauge to the cylinder whose compression is to be checked.
Compression gauge and adapter(3) Crank the engine using the starter until the needle of the compression gauge stops moving, then read the pressure indication.
Measuring compression pressure(4) If the measurement is lower than the specified limit, perform an overhaul.
(a) Measure the compression pressure of every cylinder. Measuring the compression pressure of two or three cylinders and simply assuming the compression pressures of the other cylinders is dangerous.(b) The compression pressure varies with the engine speed, so it is important to take all measurements with the same engine speed.
2Unit: MPa {kgf/cm} (psi) Take measurements with an engine speed of 240 min-1.
(a) It is important to measure compression pressures regularly and to keep track of changes in them.(b) During the engine's run-in period and after an overhaul, the compression pressures will increase slightly as the piston rings, valve seats, and other parts fit snugly in position. The Pressures will then decrease as parts wear.
Troubleshooting
Overview
Diesel-engine fault symptoms tend to have multiple causes, which influence each other. Consequently, it is often difficult to locate a fault based on the symptoms. Particular care is required when diagnosing faults related to the injection pump, injectors, and compression pressures since such faults may produce the same symptoms.For the above-mentioned reasons, the inspection sequences in the troubleshooting charts on the following pages start with items where the likelihood of a fault is greatest or with items that are easiest to inspect.Owing to their structure and combustion method, diesel engines exhibit the characteristics listed below. Familiarize yourself with these characteristics before performing troubleshooting operations.* Distinctive combustion noise (diesel knock) is emitted during normal operation.* Some black smoke is emitted during high-load operation.* Torque vibration is significant owing to the high compression pressure and high torque.* Slight hunting occurs during rapid deceleration.* Some white smoke is emitted immediately after startup when the engine is cold.
(a) The injection pump cannot be adjusted without a pump tester. Do not attempt to adjust or disassemble the injection pump during troubleshooting operations.(b) To check the combustion conditions in each cylinder, undo the cylinder's injection pipes one at a time (undoing an injection pipe stops injection in that cylinder) and compare the resulting decreases in engine speed. Retighten each injection pipe before undoing the next one.
Difficult Starting
(1) Items to Check
Before performing inspections, check for the following problems:* Clogged air cleaner element* Coagulation of engine oil* Inferior fuel* Low cranking speed(2) Inspection
Knocking
Diesel engines emit a distinctive knocking sound owing to their combustion method. This sound is normal unless it is excessive(1) Items to Check
Before performing inspections, check for the following problems:* Clogged air cleaner element* Inferior fuel(2) Inspection
Overheating
(1) Items to Check
Before performing inspections, check for the following problems:* Low