Injection Pump

CROSS SECTIONAL VIEW

REMOVAL

Remove in numerical order.

Disassemble Injection Pump

1.

Fuel Pipe

2.

Injection Pipe

3.

Vinyl Hose

4.

Control Rod

5.

Fuel Hose

6.

Oil Pipe

7.

Injection Pump

A Set No.1 cylinder piston to 10° BTDC /Compression before removing the injection pump.

10 BTDC

10 BTDC

DISASSEMBLY

Disassemble in numerical order.

Injection Pump Toyota Land Cruiser
Fig. 6-89

1.

Drain Plug

10.

Control Rack Levers

19.

Spring & Upper Seat

2.

Fuel Feed Pump

11.

Slider & Steel Balls

20.

Control Pinion & Sleeve

3.

Injection Pump Cover

12.

Ball Guide

21.

Control Rack Guide Screw

4.

Diaphragm Housing

13.

Spline Shaft

22.

Control Rack

5.

Main Spring & Adjusting Shim

14.

Injection Pump Flange

23.

Lock Plate

6.

Diaphragm & Connecting Rod

15.

Camshaft

24.

Delivery Valve, Spring & Holder

7.

DAC & Bracket

16.

Plug

25.

Delivery Valve Seat

8.

Governor Cover

17.

Tappet

26.

Cylinder

9.

Speed Control Spring

18.

Plunger & Lower Seat

Mount the injection pump on work stand, Z1X SST [09241-76021].

Remove the fuel pump with SST[09276-76010].

A Using SST [09278-46010], turn the camshaft and insert SST[09274-46010] into the tappet service openings respectively when the tappets are at their highest positions.

When a number of main spring shims are used, use special care to prevent any from being misplaced or getting mixed up.

Disconnect the diaphragm from control rack. — Caution —

Do not allow any engine oil, fuel or grease to get on the diaphragm.

Remove two control rack levers by pulling respectively upwards and downwards.

Pull out the ball guide with SST [09267-76011 ].

Remove the spring seat and slider, and then take out the six steel balls.

Take care not to allow the steel balls to drop.

Hold the spline shaft with SST[09278-46010] and remove the round nut with SST [09266 -67011],

Pull out the ball guide with SST [09267-76011 ].

Check the sliding resistance of control rack.

Sliding resistance

To prevent error upon assembling, confirm the control pinion stop position by moving control rack fully to left and right.

To prevent error upon assembling, confirm the control pinion stop position by moving control rack fully to left and right.

Hold the spline shaft with SST[09278-46010] and remove the round nut with SST[09266 -46011],

Hold the spline shaft with SST[09278-46010] and remove the round nut with SST[09266 -46011],

Pull out the spline shaft with SST[09286 -46011].

Fig. 6-100

Fig. 6-100

Measure Camshaft Thrust Clearance. [When Dial Gauge is used]

Set the magnetic base on injection pump flange and contact the dial gauge to the end of the camshaft.

Pry the camshaft with a wooden rod and check the thrust clearance. Thrust clearance

Fig. 6-101

Fig. 6-101

[When SST[09287-76010] is used]

1. Clean the injection pump flange and SST [09287-76010].

[When SST[09287-76010] is used]

1. Clean the injection pump flange and SST [09287-76010].

Fig. 6-102

Fig. 6-102

2. Firmly install SST[09287-76010] to the camshaft.

Fig. 6-103

Fig. 6-103

3. Push SST toward the pump side, and contact the outer dial to the pump flange by screwing the outer dial.

4. Read the scale on outer dial.

A unit on the outer dial scale is equivalent to indicate 0.01 mm (0.0004 in.).

Fig. 6-104

Fig. 6-104

5. Pull SST toward the front, and contact the outer dial to the pump flange by screwing the outer dial.

6. The screwing distance is camshaft thrust clearance.

Thrust clearance

Fig. 6-106
Using SST [09272-76011 ], lift the tappet to remove SST [09274-46010].

Hold the tappet in the camshaft chamber with SST[09272-76011] and take out the tappet through the camshaft bearing hole by using SST [09273-7601.1 ].

Using SST [09275-46010], hold the spring lower seat and take it out together with the plunger.

Loosen the rack guide screw and pull out the control rack.

Using SST [09275-46010], hold the spring lower seat and take it out together with the plunger.

Loosen the rack guide screw and pull out the control rack.

Remove the delivery valve holder with SST [09271-76011 ].

Fig. 6-111

Fig. 6-111

0Turn the handle of SST [09271-76011 ] screw SST into the valve seat service thread. Using the handle as lever, pull out the delivery valve seat and gasket as a set.

Fig. 6-112

INSPECTION & REPAIR

Use care not to touch the sliding surfaces of pump elements and delivery valves with your hand when handling them.

Fig. 6-113

Fig. 6-113

Wash the parts in clean light oil before inspecting. Wash and clean the outer surfaces of housings with a soft brush, and blow out the tapped holes with compressed air.

Fig. 6-114

Fig. 6-114

Diaphragm

Wipe the diaphragm with cloth. Do not allow gasoline, light oil or other petroleum products to get on the diaphragm.

Fig. 6-115

Fig. 6-115

Delivery Valve

1. Pull up the valve and close the hole at valve seat bottom end with the thumb. When the valve is released, it should sink down quickly and stop at the position where the relief ring closes the valve seat hole. If defective, replace the valve as a set.

Fig. 6-116

Fig. 6-116

Fig. 6-117

2. Close the hole at valve seat bottom end with the thumb.

Insert the valve into the valve seat and press down with finger. When the finger is released, the valve should rise back to its original position. Replace if defective.

3. Remove thumb from the valve seat hole. The valve should close completely by its own weight. Replace if defective.

Before using a new valve set, wash off the rust preventing compound with light oil or gasoline. Then re-wash with light oil and perform the above tests.

Fig. 6-118

Plunger and Cylinder

Inspect the sliding parts, and if damaged, replace the element as a set.

Fig. 6-119

Fig. 6-119

Test for fit. (Sinking test)

1. Tilt the cylinder slightly and pull out the plunger.

2. The plunger when released should sink down smoothly in the cylinder by its own weight.

3. Rotate the plunger and repeat the test at various positions. If the plunger sticks at any position, replace the element as a set.

Fig. 6-120

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