Injection Nozzle Service

Problem

Engine cranks normally but will not start.

Cause

Incorrect or dirty fuel. No fuel to nozzles or injection pump. Plugged fuel return line. Pump timing off. Inoperative glow plugs, incorrect starting procedure or internal engine problems.

Solution

Flush system and use correct fuel. Check return line clean. Retime pump timing.

Problem

Engine starts but stalls at idle.

Cause

Fuel low in tank. Incorrect or dirty fuel. Limited fuel to nozzles or injection pump. Restricted fuel return line. Idle incorrectly set. Pump timing off. Injection pump trouble. Internal engine problem.

Solution

Fill tank. Flush system and use correct fuel. Check for fuel to nozzles and to pump. Check return line clean. Reset idle. Retime pump timing. Install new pump.

Problem

Rougle idle, no abnormal noise or smoke.

Cause

Low idle incorrect. Injection line leaks. Restricted fuel return line. Nozzle trouble. Fuel supply pump problem. Uneven fuel distribution to nozzles. Incorrect or dirty fuel.

Solution

Adjust low idle. Fix leaks in injection line. Clear fuel return line. Check, repair or replace nozzle. Check, replace if necessary the fuel supply pump. Selective replace of nozzle until condition clears up. Flush system and use correct fuel.

Problem

Rough idle with abnormal noise and smoke.

Cause

Injection pump timing off. Nozzle trouble.

Solution

Retime injection pump timing. Check cylinders in sequence to find defective nozzle.

Problem

Idle is fine but misfires as throttle opens.

Cause

Plugged fuel filter. Injection pump timing off. Incorrect or dirty fuel.

Solution

Replace fuel filter. Retime injection pump timing. Flush system and use correct fuel.

Problem

Loss of power.

Cause

Incorrect or dirty fuel. Restricted fuel return line. Plugged fuel tank vent. Restricted fuel supply. Plugged fuel filter. Plugged nozzle. Internal engine problems or loss of compression and compression leaks.

Solution

Flush system and use correct fuel. Clear fuel return line. Clean fuel tank vent. Check fuel lines, fuel supply pump and injection pump. Replace fuel filter. Selective test nozzles and replace as necessary.

Problem

Noise rap from one or more cylinders.

Cause

Air in fuel system. Gasoline in fuel system. Air in high pressure line. Nozzle sticking open or with low opening pressure. Engine problems.

Solution

Check for cause and correct in fuel system. Replace fuel in fuel system. Bleed system in high pressure line. Replace defective nozzle.

Problem

Combustion noise with excessive black smoke.

Cause

Timing off. Injection pump trouble. Nozzle sticking open. Internal engine problems.

Solution

Rest idle timing. replace pump in injection pump. Clean or replace nozzle.

Disc Brake Parts

Disc Brake Parts consist of the following:

Inner Shim B
Inner Shim A
Wear Indicator
Outer Pad Shim
Caliper Bracket
Pad Retainers
Caliper Bracket
Pin Boots
Piston
Piston Boot
Brake Pads
Piston Seal
Pin A
Pin B
Bushing
Brake Hose
Sealing Washers
Bleed Screw
Caliper Body

Ignition System Service

Checking and testing of the ignition coil primary winding and secondary winding resistance. By the use of multi tester, test the resistance between positive and negative terminal of ignition coil. The test must have 1.3 to 1.6 ohms resistance. Test secondary winding resistance between positive terminal and center tower terminal. It must have 10.7 to 14.5 kilo ohms.

Check power source line using the voltmeter, check voltage at the positive terminal. Turn the ignition switch to on position, connect the positive probe of voltmeter to the negative side of terminal to engine body or ground. Approximately 12 volts power supply.

Check primary circuit by checking lose connection in the primary circuit. Battery, ignition switch, ignition coil, condenser, contact point. Grounded circuit can lead to malfunctioning of ignition system and produce spark. Check the open wire.

Check the contact point for corrosion and burns produced by the electric arcing when contact point close.

Check the distributor cap from corrosion, breaks and oil. Carbon contact at the cap center tower breaks that it cannot contact with the rotor.

Check the high tension cable from cracks, scratches, burns and open insulation. This can cause spark when it touches engine body. Test the high tension cable resistance, It must less than 25 kilo ohms.

Check spark plug by conducting spark test. Inspect spark plug gap. The gap ranges from 0.8 mm to 1.1 mm. Clean the spark plug tip. Inspect porcelain insulation for cracks.

Inspect rotor and distributor assembly. Check rotor tip from corrosion or bend. Check also distributor shaft for play. Condenser wire and contact point wire must not be grounded at distributor body.

Ignition System

Ignition came from a word ignite which means to set on fire. This system provides spark by the use of spark plug to burn the air and fuel mixture in the combustion chamber of an engine. The system operates by transforming 12 volts battery power to thousands of volts, enough to produce spark at the spark plug gap.

Components of Ignition System

Battery is the source of electrical power. The battery continually supplies electrical power needed by the system.

Ignition switch control the ignition system and other electrical circuits. Also called an automobile main switch.

Ignition coil is a transformer type device that transform the 12 volts battery power to 30,000 up to 60,000 volts. The coil is composed of two winding, the primary and secondary winding.

Distributor assembly is a device that distribute high voltage to the different spark plugs. It has also mechanism that advances the delivery of spark when engine is at higher RPM. The distributor also shaft opens and closes the contact point.

Contact point closes and opens the primary circuit to the ground so that the ignition coil can increase the voltage supplied by the battery.

Condenser is a device that absorbs and reduce electric arc when contact point closes.

High Tension Cables is the high voltage path from ignition coil secondary terminal to distributor cap center tower to different spark plug.

Spark plug is the device installed at the engine body and deliver high voltage to the combustion chamber by spark to ignite the air and fuel mixture.