Toyota Camry 1983-1996 Repair Guide

Injection Pump

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CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

REMOVAL & INSTALLATION



See Figures 1, 2 and 3

  1. Disconnect the negative battery cable. Drain the cooling system.
  2.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.



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Fig. Fig. 1: Exploded view of the diesel injection pump and drive pulley

  1. Disconnect the accelerator and cruise control cables from the pump.
  2.  
  3. Disconnect the throttle sensor harness.
  4.  
  5. Disconnect the water by-pass hoses, the boost compensator hoses, the A/C or heater idle-up vacuum hoses and the heater hose.
  6.  
  7. Remove the injector pipes.
  8.  
  9. Remove the injection pump drive pulley as described in this Section.
  10.  
  11. Matchmark the raised timing mark on the pump flange (injection period line) with the block. Unbolt and remove the pump.
  12.  



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Fig. Fig. 2: Matchmark the index mark of the pump flange to the block



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Fig. Fig. 3: Location of the pump bracket bolts A and B

To install:
  1. Align the injection period line on the injection pump and water pump assembly.
  2.  
  3. Loosen the pump bracket bolts marked A in the illustration and ensure that there is no clearance between the bracket and the stay, and tighten the bolts.
  4.  
  5. Temporarily tighten the mounting bolt marked B . This bolt will be tightened to specification when the timing is adjusted.
  6.  
  7. Install the injection pump drive pulley.
  8.  
  9. Install the injection pipes.
  10.  
  11. Connect all the hoses and fill the cooling system to the proper level.
  12.  
  13. Prime the injection pump by operating the priming pump located on top of the fuel filter. Prime the pump until you can feel resistance.
  14.  

  1. Connect the negative battery cable.
  2.  
  3. Bleed the system by loosening the pipes at the nozzles and cranking the engine until all air is expelled and fuel sprays.
  4.  
  5. Connect the ground strap and install the water by-pass support.
  6.  
  7. Install the current sensor plate.
  8.  
  9. Install the electronic vacuum regulating assembly, pipe and hoses.
  10.  
  11. Connect the throttle position sensor harness.
  12.  
  13. Connect the throttle cable to the injection pump.
  14.  
  15. Connect the accelerator or cruise control cable and rod to the injection pump.
  16.  
  17. Check the engine idle and maximum idle speeds.
  18.  
  19. Check the coolant level and add as necessary.
  20.  

INJECTION TIMING



See Figures 4, 5 and 6

This procedure requires the use of a plunger stroke measuring tool and dial indicator.

  1. Remove the injection pump head bolt and install stroke measuring tool (SST 09275-54010) or equivalent, along with the dial indicator.
  2.  
  3. Turn the crankshaft clockwise with a socket wrench to set No. 1 or No. 4 cylinder to approximately 2530° BTDC on the compression stroke.
  4.  



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Fig. Fig. 4: Installing the stroke measuring tool with the dial indicator for setting the injection pump timing



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Fig. Fig. 5: Setting the crankshaft 25-30 degrees BTDC on the compression stroke

  1. Use a screwdriver to turn the cold start lever 20° counterclockwise, then place a metal block 8.510.0mm thick between the cold start lever and thermo wax plunger.
  2.  



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Fig. Fig. 6: Open the cold starting lever and insert a 0.33-0.39 inch (8.5-10.0mm) block

  1. Zero the dial indicator, then check to make sure the indicator remains at zero while rotating the crankshaft pulley slightly to the left and right.
  2.  
  3. Slowly rotate the crankshaft pulley until the No. 1 or No. 4 cylinder comes to TDC of the compression stroke, then measure the plunger stroke. It should read 0.70mm on the dial indicator.
  4.  
  5. To adjust the injection timing, loosen the four injection lines and the union bolt of the fuel inlet line. Loosen the injection pump mounting bolts and nuts.
  6.  
  7. Adjust the plunger stroke by slightly tilting the injection pump body. If the stroke is less than specifications given above, tilt the pump toward the engine. If greater than specifications, tilt the pump away from the engine.
  8.  
  9. Once the pump stroke is within specifications (as described in Step 5), tighten the injection pump mounting bolts and nuts. Tighten the bolts to 34 ft. lbs. (46 Nm) and the nuts to 13 ft. lbs. (17 Nm) Tighten all union nuts and bolts to 22 ft. lbs. (29 Nm).
  10.  
  11. Remove the metal plate from the cold start lever and the pump stroke measuring tool from the injection pump. Install the distributor head bolt and tighten to 12 ft. lbs. (16 Nm). Replace the head bolt washer when installing. Bleed any air from the injection pump by cranking the starter motor, then start the engine and check for leaks.
  12.  

 
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