Republic of the Philippines

Division of Davao City

TOYOZU TECHNICAL SCHOOL FOUNDATION INC.
#25 Dacudao Avenue Agdao, Davao City

JOINT DELIVERY VOUCHER

PROGRAM (JDVP)
(AUTOMOTIVE SERVICING NC I)

DAVAO CITY NATIONAL HIGH SCHOOL

Batch 2020 - 2021
WEEK 3

MARCEL B. IMPERIAL
Automotive Servicing NC I & NC II Trainer
Automotive Servicing NC I
JDVP Training (Day 5)
Lesson 6: Set and Install Injection Timing

Learning Outcomes
At the end of this lesson, the learners will be able to:
1. Discuss the function and types of diesel fuel system
2. Identify the main components of diesel fuel system
3. Perform injection timing in diesel engine

Abstraction
What is diesel fuel system?
Diesel fuel system is a well-designed mechanism for admitting fuel into an I.C. engine.
Diesel engine has force air by intake valve into the cylinder. High compression ratio heats the
air enough to ignite the fuel. Diesel fuel is injected into the cylinder at high pressure. The
amount of fuel injected suits to the load and controls engine speed.
 Basic diesel fuel system is divided in two sections:
 Low pressure side
 Clean the fuel
 Deliver fuel to high pressure side
 High pressure side
 Raise the fuel pressure high enough to injection stage

History and Development

 Herbert Akroyd Stuart developed the first system laid out on

modern lines with a highly accurate 'jerk pump' to meter out fuel
oil at high pressure to an injector. This system was adapted and
improved by Robert Bosch and Clessie Cummins for use on
diesel engines — Rudolf Diesel's original system employed an
'air-blast' system using highly compressed air.
 Fuel injection was in widespread commercial use in diesel engines by the mid-1920s.
Because of its greater immunity to wildly changing g-forces on the engine, the
concept was adapted for use in gasoline-powered aircraft during World War II, and
direct injection was employed in some notable designs.

Objectives of Diesel Fuel System

1. The diesel fuel system of the compression ignition engine should fulfill the following
objectives consistently and precisely:
2. Meter the appropriate quantity of fuel, as demanded by the speed of, and the load
on, the engine at the given time.
3. Distribute the metered fuel equally among cylinders in a multi-cylinder engine. Inject
the fuel at the correct time (with respect to crank angle) in the cycle.
4. Inject the fuel at the correct rate (per unit time or crank angle degree).
5. Inject the fuel with the correct spray pattern and sufficient atomization as demanded
by the design of the combustion chamber.
6. Begin and end injection sharply without dribbling.

Main Component Parts of Fuel Injection System

Main components of fuel system of diesel engine are:

Fuel tank
Basically, it is a holding tank
of your diesel fuel. When you fill up
at a gas station the diesel fuel travels
down the filler tube and into the tank.
In the tank, there is a sending unit
which tells the fuel gauge of how
much diesel fuel is in the tank.

Feed Pump/Priming Pump

It is a fuel transfer pump can be operated by hand to pump fuel when
bleeding the system. It draws diesel fuel from fuel tank through primary filter and
also assures the diesel fuel supply to injection pumping elements.
Fuel Filter
Clean diesel fuel is critical to engine life
and performance. Fuel injectors that have tiny
openings which clog easily, so filtering the diesel
fuel is a necessity. Filters can be before or after
the fuel pump, sometimes both. They are most
often made from a paper element, but can be
stainless steel or synthetic material and are
designed to be disposable in most cases.

Water Separator
It collects water and dirt particles which cause the engine
to run poorly or damage the injection equipment.

Injection Pump
It distributes/sent diesel fuel to each injector which
has high pressure, controlled quantities of diesel fuel at
the right time. The high injection pressures needed to
exceed the compression pressure in the combustion
chamber. And also break up the diesel fuel into small
particles or atomize.

Common Types of Injection Pump

1. Inline Injection Pump – is more “rectangular” or square in shape with the
fuel fittings arranged in a straight line.

2. Rotary Injection Pump – is a “round” in shape with the fuel fittings arranged
around the pump.
 High Pressure Tube/Hydraulic Tube
This tubes/pipes which carries the
pressurized diesel fuel from one
another/parts.

Fuel injectors nozzle

The fuel injector is basically a tiny pipe
valve which opens and closes with a
pressurized fluid from the injection pump to
the pre-combustion chamber.

Two Types of Fuel Injector Nozzle

 Hole type – used for engines with pre-
combustion chambers.

 Pintle type – produces a hollow

sprays; used for engine with pre-
combustion chambers.

Operation of an Injection Nozzle

 Hydraulically or pressure operated by
fuel delivered from the injection
pump.
 Spring load valve is lifted allowing pressurize fuel to spray out through
one or more orifices into combustion chamber.

Note: Some injection nozzles have adjustable valve lifts. Refers to

manufacturer’s service manual.

Glow Plug
It is to make cold starting easier. It assists with heating the
combustion chamber about 1,500 oF. It may continue to operate
after the engine has started. It also requires high electrical load.

Type of Injection Timing

A. Timing Gear – it is a gear meshing type where the gear drive the other
gear and also have their timing marks that align to each other.
 B. Timing Belt – it is toothed belt that drives the gear pulley of crankshaft, camshaft and
injection pump where in the timing marks of pulley are align to the timing mark on the
engine body.

C. Timing Chain – it is chain type that drives the sprocket of the camshaft and crankshaft.
And also the sprocket has a timing mark.

Procedures in Setting Injection Timing

Injection Timing in 4BA1

1) Remove the battery cable. It should remove first the negative (-) cable and then the
positive (+) cable.

2) Remove the nut on the valve cover (red).

3) Rotate the crankshaft pulley in clock-wise direction.

4) Observe the timing mark indicator of the crankshaft pulley to its timing mark and also
the timing mark of injection pump.

5) Once the timing mark take its place. Check the valve movement. It should be the
piston #1 will be top (End of Compression Stroke).

Piston #1 Valve
 Intake valve (Closed)
 Exhaust valve (Closed)

Piston #2 Valve
 Intake valve (Closed)
 Exhaust valve (Open)

Piston #3 Valve
 Intake valve (Open)
 Exhaust valve (Closed)

Piston #4 Valve
 Intake valve (About to Open)
 Exhaust valve (About to Close)

6) Install the valve cover.

7) Conduct bleeding so that the trap air that occupied in the fuel system which should
 be remove in the system.

Steps in Bleeding
a. Open the bleeder screw of the injection pump.
b. Loosen the plastic/metal cap of feed pump.
c. Then, start to pump it, until the air lack remove inside the fuel system.
d. Once the diesel fuel is pure out of air lack which seen in the bleeder hole, you
may close the bleeder hole.
e. After that, slowly pump the feed pump, until it slowly hard to pump it and close
it.

8) Attach the battery cable, it should first the positive (+) cable to be install and last the
negative (-) cable.
9) Go to your ignition switch (susian), twist the key in counter-clockwise direction which
allow the glow plug heat air in the combustion chamber. If the car does not have a
heater in ignition switch, you may direct a wire (#14 AWG) from glow plug to the
battery and count 10 to 15 seconds so that the air in combustion chamber is heated.

10)After the engine is pre-heated, you may twist the ignition switch in clock-wise
direction to start the engine.
11)Once the engine start, release the ignition switch by your hand.

Note: If you did twist longer time the ignition switch while the engine is running. It can
cause of damage to the gear teeth of the starter motor.

12)If you shut down the starting engine, go to your injection pump and push down the
engine stop lever or cover the opening hole of intake manifold.

Note: If you push down the engine stop lever in injection pump, it will close the supply
of diesel fuel in the fuel injectors. If you cover the opening hole of the intake manifold,
 it will stop the entering of air in combustion chamber which needed in burning the
diesel fuel.
Injection Timing of 4DR5
1) Remove the battery cable. It should remove first the negative (-) cable and then the
positive (+) cable.
2) Remove the nut on the valve cover.
3) Remove the nut and crankshaft pulley.

4) Remove the clutch fan to its pulley.

5) After the fan is being removed, remove the gear plate cover of the injection pump,
crankshaft, camshaft and idler gear. Install again the nut of crankshaft.

6) Rotate the crankshaft. Match up the timing mark of the gear in injection pump,
crankshaft and camshaft to the idler gear which at the center. (Timing Mark: 123)
7) Once the timing mark take its place. Check the valve movement. It should be the
piston #1 will be top (End of Compression Stroke).
8) Uninstall again the nut of the crankshaft and also return the gear plate cover the
same as the clutch fan.
9) Install the valve cover.
10)Conduct bleeding so that the trap air that occupied in the fuel system which should
be remove in the system.

Steps in Bleeding
a. Open the bleeder screw of the injection pump.
b. Loosen the plastic/metal cap of feed pump.
c. Then, start to pump it, until the air lack remove inside the fuel system.
d. Once the diesel fuel is pure out of air lack which seen in the bleeder hole, you
may close the bleeder hole.
e. After that, slowly pump the feed pump, until it slowly hard to pump it and close
it.

11)Attach the battery cable, it should first the positive (+) cable to be install and last the
negative (-) cable.
12)Go to your ignition switch (susian), twist the key in counter-clockwise direction which
allow the glow plug heat air in the combustion chamber. If the car does not have a
heater in ignition switch, you may direct a wire (#14 AWG) from glow plug to the
battery and count 10 to 15 seconds so that the air in combustion chamber is heated.
13)After the engine is pre-heated, you may twist the ignition switch in clock-wise
direction to start the engine.

14)Once the engine start, release the ignition switch by your hand.

Note: If you did twist longer time the ignition switch while the engine is running. It can
cause of damage to the gear teeth of the starter motor.

15)If you shut down the starting engine, go to your injection pump and push down the
engine stop lever or cover the opening hole of intake manifold.

Note: If you push down the engine stop lever in injection pump, it will close the supply
of diesel fuel in the fuel injectors. If you cover the opening hole of the intake manifold,
it will stop the entering of air in combustion chamber which needed in burning the
diesel fuel.
Injection Timing of Toyota 1C
1) Remove the battery cable. It should remove first the negative (-) cable and then the
positive (+) cable.

2) Remove the nut on the valve cover.

3) Remove the nut and crankshaft pulley.
4) Remove the clutch fan to its pulley.
5) After the fan is being removed, remove the gear plate cover of the injection pump,
crankshaft, camshaft and idler gear. Install again the nut of crankshaft.

6) Rotate the crankshaft. Match up the timing mark of the gear teeth pulley of injection
pump, crankshaft and camshaft to the timing mark of the engine body.

7) Once the timing mark take its place. Check the valve movement. It should be the
piston #1 will be top (End of Compression Stroke).

Piston #1 Valve
 Intake valve (Closed)
 Exhaust valve (Closed)

Piston #2 Valve
 Intake valve (Closed)
 Exhaust valve (Open)
Piston #3 Valve
 Intake valve (Open)
 Exhaust valve (Closed)

Piston #4 Valve
 Intake valve (About to Open)
 Exhaust valve (About to Close)

8) Uninstall again the nut of the crankshaft and also return the gear plate cover the
same as the clutch fan.
9) Install the valve cover.

10)Conduct bleeding so that the trap air that occupied in the fuel system which should
be remove in the system.

11)Attach the battery cable, it should first the positive (+) cable to be install and last the
negative (-) cable.
12)Go to your ignition switch (susian), twist the key in counter-clockwise direction which
allow the glow plug heat air in the combustion chamber. If the car does not have a
heater in ignition switch, you may direct a wire (#14 AWG) from glow plug to the
battery and count 10 to 15 seconds so that the air in combustion chamber is heated.

13)After the engine is pre-heated, you may twist the ignition switch in clock-wise
direction to start the engine.
14)Once the engine start, release the ignition switch by your hand.

Note: If you did twist longer time the ignition switch while the engine is running. It can
cause of damage to the gear teeth of the starter motor.

15)If you shut down the starting engine, go to your ignition switch and turn off (counter-
clockwise).
Post Test 6.1
Direction: Choose the letter of your best answer. Write the answer on yellow paper.
1. Glow plug is used for ________.
a. heating crankcase b. igniting diesel fuel c. easy starting d. gas engine
2. Diesel fuel is burned by____
a. pressure of piston b. heat of injection
c. pressure and temperature of air d. pressure of diesel fuel
3. 4DR5 timing marks are_____
a. letters b. numbers c. words d. love quotes
4. Fuel used in diesel engine.
a. Petroleum b. crude oil c. diesel fuel d. gasoline
5. When piston No. 1 is performing intake stroke, piston No. 4 is ______.
a. Compression b. power c. exhaust d. intake
6. When piston No. 3 is performing compression stroke, piston No. 2 is ______.
a. Compression b. power c. exhaust d. intake
7. Why is it that the exhaust valve has thicker clearance compare to intake valve?
a. so that the exhaust valve will run cooler
b. because the intake valve is bigger in diameter than exhaust valve
c. for easy exit of burnt gases
d. not mentioned
8. A tool used to adjust valve clearance.
a. Wire gauge b. dial gauge c. metal gauge d. feeler gauge
9. Injects atomize diesel fuel to combustion chamber.
a. Injector b. injection pump c. governor d. plunger
10. Engine power depends on:
a. Amount of air entered b. amount of fuel injected
c. viscosity of oil d. type of fuel used
11. Injector is opened by:
a. Pressure of fuel b. magnet c. pressure of air d. force of spring
12. There are three elements of fire: namely air, heat and _________.
a. Fuel b. gas c. water d. soil
13. Which statement is TRUE?
a. diesel engine burns air and fuel mixture inside the combustion chamber
b. during power stroke, there is a spark from injector that burns the diesel fuel
c. diesel engine compresses only pure air during compression stroke
d. glow plug is not needed for indirect injection diesel engine
14. 4BA1 timing marks are_____
a. love quotes b. numbers c. words d. letters
15. Which of the following is ALWAYS TRUE about diesel engine?
a. All diesel engines are used for heavy duty vehicle
b. All diesel engine uses glow plug
c. Diesel fuel is injected during power stroke
d. All of the above

Post Test 6.2

Direction: Arrange the following events. Rewrite it on yellow paper according to its order.

1. From BDC, piston travels upward and both valves are closed.
2. 12 degrees before compression stroke ends, atomized diesel fuel is injected.
3. Piston travels downward and intake valve is open.
4. Piston compresses air until pressure and temperature is high.
5. Air alone enters the combustion chamber.
6. From BDC, piston travels upward and exhaust valve is opened. Burnt gases escape the
cylinder through exhaust port, exhaust manifold, exhaust pipe, muffler and exits to the
atmosphere through tail pipe.
7. When the piston reaches BDC, intake stroke ends.
8. Atomized diesel fuel is ignited by air temperature.
 9. Expanding pressure due to combustion pushes the piston downward.
10. When the piston reaches BDC, power stroke ends.
Automotive Servicing NC I
JDVP Training (Day 5)
Lesson 7: Perform Bleeding Air in Diesel Engine

Learning Outcomes
At the end of this lesson, the learners will be able to:
1. Discuss the principle of diesel fuel system
2. Perform bleeding process in diesel engine
3. Explain the different problems of diesel fuel system

Abstraction

Often, engine starting problems, are caused by small amounts of air in the fuel. A
common cause of this problem is when you run out of fuel, if this happens you will need to
know how to “bleed” your engine, which rids the fuel lines of air, so the engine can start.
If you are an owner of a diesel engine bleeding is an essential skill. If you are familiar
with the manufacturer’s recommended procedure for bleeding your engine, follow it, but
generally, the procedure is as follows.
When bleeding the fuel line, especially when the starter motor is used to operate the fuel
lift pump, wrap rags around all venting units to collect excess diesel fuel that splashes out.

Principle of Diesel Fuel System

1. When the engine start, the feed pump of injection pump will start to suction the diesel
fuel from fuel tank.
2. After the diesel fuel suction, the fuel tank will supply a fuel to the feed pump and deliver
it to the primary and secondary fuel filter.
 Note: The primary fuel filter has water separators which filter the water mixed to the fuel
and also the dirt. The secondary fuel filter has priming pump which allow the fuel suction
and deliver it to the injection pump (Plunger). Secondary fuel filter is also filter dirt.

3. Once the fuel deliver in injection pump, the injection pump will produce pressurized
diesel fuel into its injector plunger

4. The pressurized diesel fuel will deliver to the fuel injector.

5. The fuel injector will release the pressurized diesel fuel in the pre-combustion chamber
of the engine (cylinder).
6. After the fuel injector release the pressure, the pressure will low due to the injector
plunger close. The low pressure fuel inside the fuel injector will go out to the return port
of injector and back to the fuel tank.

7. Once the low pressure fuel return, it will again suction back to the other parts of fuel
system.

Some Different Problems of Diesel Fuel System

Problem #1 – Dirty Fuel

A clean diesel fuel pump injector is a happy diesel fuel pump injector. Over time,
residue can build up in the fuel system, and enough gunk, grime and grease can clog up
the entire fuel injector pump. The spray tip (where the fuel leaves the injector and enters
the combustion chamber) is particularly prone to “backing up,” so to speak.

If your engine has ever sputtered or hesitated during acceleration, a clogged fuel
spray tip might be the glitch. And it all starts with subpar diesel fuel. In 2006, diesel fuel
production was tweaked to compensate for ultra low sulfur diesel fuel (ULSD), and diesel
engine owners have noticed more “dirty fuel” difficulties than before.

Problem #2 –Low Fuel Tank Level

If your main goal in life was to destroy diesel fuel pump injectors, you’d run your
car with the fuel tank as close to empty as possible. It all has to do with lubrication. With
 plenty of diesel fuel in the tank, the fuel pump bearings receive plenty of lubrication. With
a near-empty tank, the fuel system is suddenly pushing air instead of diesel fuel.
Anything but diesel fuel can wear out the fuel pump bearings, which means the fuel
injectors will not receive the fuel at the pressurized level (30,000 psi, 40,000 psi, etc.) it
should be.

Problem #3 – Foreign Object Inside Injector

Diesel fuel pump injectors are high-precision components. They also deal with a
tremendous amount of motion and other stresses. One small visitor inside (a piece of
dust, debris, etc.) can clog the injector. Worse yet, a microscopic object can leave the
injector open all the time. If the injector can’t close, cylinder performance is
compromised.

Problem #4 – Bad Injector Timing

Whenever the fuel injector pump’s O-rings or ball seats are defective, the timing
of the fuel transfer process is disrupted. This is a common diesel fuel injector pump
glitch, and usually requires a complete injection pump rebuild or replacement.

Maintenance Reminder

Here’s the good news about fuel injector pump problems: avoiding disaster is
simple. In fact, if you do these three things, you’ll enjoy great performance and minimal
repair costs:

 Purchase clean, reliable fuel

 Change your fuel filter every 40,000 miles
 Keep your fuel tank at least one-quarter full most of the time

Post Test 7.1

Direction: Identify the following main components of diesel fuel system.

Post Test 7.2

Direction: True or False. Write T if the statement is true. If false write F otherwise. Write your
correct answer on the right side of the sentence. (2 points each)

______1. Diesel engine uses diesel fuel.

______2. During intake stroke of diesel engine, air and fuel admitted inside the combustion
chamber.
______3. Fuel in diesel engine is burned by heat of electricity.
______4. Diesel fuel is injected during power stroke.
______5. Bleeding is a process of removing excess diesel fuel.
______6. When the diesel engine lacks bleeding, engine will not start easily.
______7. During intake stroke, only air is admitted inside the combustion chamber of diesel
engine.
______8. Compression ratio is the ratio of the volume of air above the piston when it is on
BDC against the volume of air above the piston when it is on TDC.
______9. The lower the compression ratio, the greater the power engine has.
______10. Diesel is ignited by the heat of compression.