Diesel Engine Fuel Supply System

Ruifeng Commercial Vehicle Maintenance Manual Fuel System (diesel)
Section II Diesel engine fuel supply system

I. General
1. Brief introduction
Diesel engines use diesel as fuel. Indices for evaluation are:
1. Ignition quality: evaluation of diesel spontaneous ignition capability (indicated by cetane value).
2. Evaporation
3. Viscosity: measurement of fuel fluidity.
4. Condensation point: temperature at which diesel starts to loss its fluidity.
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Diesel engine and gasoline engine basically have the same structure. Both consist of cylinder block, cylinder head,
piston, valve, crank, crankshaft, camshaft, and flywheel etc. However, the former uses compression-ignited diesel
to do work, while the latter uses ignited gasoline to do work. The essential difference is between “compression
ignition” and “lighted ignition”.
Gasoline engine fuel is mixed with air in air intake stroke and then enters cylinder, where it is ignited by spark
plug to do work. Diesel engine fuel is directly injected into cylinder near end of compression stroke, where it is
ignited by compression in compressed air. Due to this difference, diesel engine has its characteristics in structure
of fuel supply system. Fuel injection system of diesel engine consists of fuel injection pump, fuel injector, high
pressure fuel pipe and some auxiliaries.
Simple process of diesel engine fuel transmission: the fuel transfer pump delivers diesel to the filter. After
filtering, the diesel will enter fuel injection pump (to ensure sufficient fuel and maintain certain pressure, it is
required that fuel supply by fuel transfer pump is much higher than demand by injection pump, surplus diesel will
return to fuel tank via low pressure pipe and other part will be compressed to high pressure by injection pump),
pass HP fuel pipe, and then enter injector for direct injection into cylinder combustion chamber for compression
ignition.
To allow stable operation of diesel engine at idling speed and limit engine overspeed, fuel injection pump is
provided with governor. Fuel injection pump is the most precise part of diesel engine fuel supply system and its
function is to adjust amount of diesel according to change of diesel engine operating conditions, increase diesel
pressure, and supply diesel to injector according to set time and rule.
2. Size and parameters

Fuel injection pump
Injection pump
Type Distributed type
Rotation direction Clockwise as seen from drive end
Fuel injection sequence 1-3-4-2
Type of governor Centrifugal
Type of timer Hydraulic type
Type of fuel transfer pump Blade type
Control device
Fast idling speed mechanism Manual
Nozzle and seat
Type Rotary tightening type
Nozzle
Type Throttling type
Engine control system Pedal-controlled pull wire type
Fuel tank
Volume (L) 65
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3. Maintenance size and parameters

Standard value Limit value
Fuel injection
Injection timing (when plunger is lifted by 1mm) 4º after TDC
Cam lift mm 2.2
Plunger diameter mm 10
Fuel supply valve opening pressure kPa (…) 2.150
Fuel cutoff EM valve Rated voltage: 12V
Resistance: 8Ω
Fuel injection nozzle

Injection hole (number-dia.) mm 1-1.02
Fuel injection pressure kPa (…) 12,000-13,000 11,000
Idling speed rpm 750±30
Engine control system
Pull wire length
Acceleration control wire mm L:2725-2735
A+B:125-129
Throttle pull wire mm L:642-648
C:60-62
Throttle button stroke 25 or larger
4. Torque parameters
Nm
Fuel injection pipe clamp bolt 4-6
Fuel injection pipe connector and nut 23-37
Bolt between pump support and body 18-25
Bolt between injection pump and pump support 20-27
Injection pump mounting nut 15-22
Fuel return pipe nut 30-40
Injection nozzle 50-60
Positioning nut and nozzle 35-40
Pump sprocket nut 80-90
Fuel tank mounting bolts 15-22
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5. Special tool
Tool (No. and name) Picture Purpose
09310-43000 Fuel injection timing adjustment
Pre-travel measurement connector
09314-43000 Removal of injection pump sprocket

Injection pump sprocket puller
6. Fuel supply system

Distributed type fuel injection pump is installed on front upper tank and driven by timing belt. Fuel is pumped
from fuel tank by a pump in fuel injection pump and sent to the fuel injection pump via a small filter complete
with oil-water separator. The fuel is then pressed into pump chamber. Fuel is sent from pump chamber to the HP
room above plunger via distributor head pipeline and plunger sleeve. The plunger pumps fuel so that HP fuel is
injected from nozzles according to injection sequence. Surplus fuel in pump chamber will return to fuel tank via
overflow valve and pipeline. Injection pump relies on fuel circulation cooling and lubrication. Surplus fuel in
nozzle holder returns to fuel tank via overflow pipe and injection pump connector. Since injection pump is
lubricated by fuel, water in fuel will greatly reduce pump service life. Therefore, special attention shall be paid to
prevent oil and dust from entering the system.
Overflow pipe Oil supply pump (air outlet)

Nozzle
Fuel Water level

filter warning light
Injection
pump
Fuel injection
pump
Fuel tank
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切断阀
Stop valve
Fuel
喷油嘴
injection
VE inject valve nozzle
VE 喷射泵
Oil return pipe

回油管
油箱
Fuel tank
柴油格
Diesel filter
7. Common troubleshooting
Fault Possible causes Repair
Engine Starting speed too low Repair starting system or charge/replace batteries so that engine
cannot can start at minimum 150rpm
start No voltage at fuel cutoff solenoid Check voltage with testing lamp; replace fuse/faulty line if
valve in fuel injection pump required
Loose or faulty fuel cutoff solenoid Tighten solenoid valve. Check valve noise when switch
valve in fuel injection pump operates (open or close). Replace faulty solenoid valve.
No voltage at preheat plug bus With switch “On”, if testing lamp shows no voltage at bus, test
relay and circuit.
Faulty preheat plug Perform test; replace preheat plug if required
Air in fuel system Vent air from fuel system
Injection pump not supplying fuel If no fuel comes out from soft injection pipe during starting,
check timing belt and fuel supply from filter
Wrong connection of injection pipe Connect fuel pipe at correct position
Incorrect fuel injection timing Adjust fuel injection timing
Faulty injection nozzle Check and repair/replace nozzle as required
Aforesaid engine mechanism fault Test cylinder compression pressure; repair engine if required
Faulty injection pump Try to start engine with a new pump; replace old pump if
required
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Incorrect Idling speed incorrectly adjusted Check and adjust idling speed if required
or poor Poor throttle control Check that accelerator rod on pump is not loose;
idling then adjust throttle pull wire
speed Loose fuel hose between filter & injection pump Replace or clamp hose; vent air from the system
Air in fuel system Vent air from fuel system
Insufficient fuel supply due to clogged fuel Check and replace line, hose or fuel filter if
filter, leakage in fuel loop and injector pipe, dirt required
accumulation, winding or connector squeezing
Faulty nozzle Check and repair or replace nozzle if required
Aforesaid engine mechanism fault Test compression pressure; repair engine if
required
Faulty fuel injection pump Use new pump to test engine at idling speed;
permanently replace pump if required
Excessive engine loading Observe for correct shifting speed
Smoking Engine not reaching correct operating Check and replace cooling system thermostat if
exhaust temperature required
(black, Incorrect highest rotation speed Check and replace injection pump if required
blue or Incorrect fuel injection timing Adjust fuel injection timing
white) Clogged exhaust system Check this system for depression and clogging
Aforesaid engine mechanism fault Measure cylinder compression pressure and
replace engine if required
Faulty fuel injection pump Install new pump and observe exhaust; replace
pump permanently if required
Low power Injection pump acceleration rod loose or not Tighten the rod, check for jamming of pedal
output and reaching max. rotation speed adjusting screw stroke and then adjust throttle pull wire
slow Incorrect max. rotation speed Check and replace injection pump if required
acceleratio Dirty air filter Clean or replace filter element
n Insufficient fuel supply due to clogged fuel Check and replace line, hose and fuel filter if
(speedomet filter, leaking fuel loop and injection pipe, dust required
er is accumulation, winding, and connector
accurate squeezing
and clutch Air in fuel system Vent air from fuel system
is not Ice or solidified wax in fuel pipeline (in winter) Move vehicle to warm garage till ice or wax
slipping) melts. Vent vapor from fuel system.
Faulty injection nozzle Check and repair/replace nozzle if required
Aforesaid engine mechanism fault Test cylinder compression pressure; repair
engine if required.
Faulty injection pump Use new pump to check acceleration and speed.
Replace pump permanently if required
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Excessive fuel Dirty air filter Clean or replace air filter element
consumption Leakage of fuel Check and replace or tighten all pipelines, hoses
and connectors if required.
Fuel return pipeline and hose clogged Check fuel return pipeline for winding and
depression. Replace faulty line. If line is clogged,
blow with compressed air and then vent air from
system.
Idling speed or max. rotation speed too Check and adjust idling speed or replace injection
high pump if required
Faulty injection nozzle Check and repair or replace injection nozzle if
required
Aforesaid engine mechanism fault Test compression pressure and repair engine if
required
Faulty injection pump Fit new pump to check fuel consumption; replace
pump permanently if required
Throttle pedal Pedal arm rusted Clean or lubricate
requiring too Incorrect path Ensure bending radius greater than or equal to
large stepping 150mm and correct excessive bending
force (incl. Pull wire rusted Replace
pedal cannot Throttle pull wire displaced Lubricate connecting rod and shaft
fully retreat)
Broken throttle Jammed pull wire end Remove rust and burr on pull wire end
control pull Incorrect pull wire end fixing point Correct end at shifting lever side
wire perpendicularity
Incorrect perpendicularity between pull Correct or replace parts
wire end and pull wire
Engine cannot Fault in starting switch operation Repair or replace parts
be stopped Broken harness between starting switch Replace harness
and fuel cutoff solenoid valve
II. Inspection and adjustment

Throttle pull wire Adjusting
1. Preheat engine till stabilized at idling speed; nut
2. Confirm idling speed at specified value;
3. Stop engine;
4. Confirm no apparent bend of inner pull wire
5. Check inner pull wire and correct its slack
Locknut
6. If too loose, adjust as follows:
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1） Loosen adjusting nut to fully approach

accelerator rod;
2） Tighten adjusting nut till accelerator rod just
starts to move;
Rotate in reverse direction for one round and lock
with lock nut. Adjust accelerator pull wire gap to
standard value.
Standard value: about 1 mm

3) Adjust so that when accelerator rod is fully open,
throttle pedal stopper is in contact with pedal arm.
4) After adjustment, confirm that by means of
pedal, accelerator rod can be fully open and closed.
Adjustment
Venting of air from fuel pipeline
After the following maintenance, vent air:
● draining ad refilling of fuel during maintenance;
● replacement of fuel filter;
● removal of main fuel pipeline.
1. Remove air plug of fuel filter
2. Place cleaning cloth around air plug and
repeatedly operate hand pump till no bubble
comes out of the hole; tighten air plug.
3. Repeat these operations till it is difficult to
operate the hand pump.
Adjustment
Draining of water from fuel filter
If fuel filter indicator lights up, there is water in
the filter. Use the following steps to drain water:
1. Loosen drain plug;
2. Use hand pump to drain water; tighten the plug
by hand.
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Inspection and adjustment
Nozzle
Pressure of start of injection
1. Fix nozzle on nozzle tester and check the
following.
2. Move nozzle tester handle at about one stroke
per second.
3. When fuel is injected, pressure gauge pointer
slowly rises and sways. Take the reading at
the position where the pointer starts to sway.
Check if pressure of start of injection is
within standard value.
Standard value: 12,000-13,000 kPa
Limit value: 11,000 kPa or less
4. If nozzle is faulty, remove it and adjust

injection pressure to standard value by
changing shimming thickness. For every
0.1mm increase of shimming thickness, fuel
injection pressure will increase by about 1000
kPa.
Caution:
When removing nozzle, keep dirt and water off.
5. If pressure of start of injection can not be
adjusted by changing shimming thickness,
replace nozzle assembly.
Fuel injection status
1. Move nozzle tester at about one stroke per
second.
[Needle valve vibration]
When operating the handle, if special intermittent
noise is heard, fuel injection is normal. Needle
valve vibration shall be felt at handle.
[Fuel beam]
During testing, check if fuel beam is ideal. As
shown in the figure, fuel beam may be of spiral
shape with atomizing process. This is normal in
such test and nozzle function is normal.
2. Move nozzle tester handle at 4 to 6 strokes
per second.
3. Confirm that fuel beam has about 15º taper;
this indicates good injection status.
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1. If injection is not good, remove nozzle and

replace nozzle or the whole assembly.
2. After confirmation of injection, there shall be
no dripping of fuel.
3. In case of dripping, remove nozzle and replace
nozzle or the whole assembly.
Nozzle oil seal

1. Use nozzle tester to maintain nozzle internal
pressure (indicated by pressure gauge) at
10000-11000 kPa. In this state, check for fuel
leakage from nozzle.
2. In case of leakage, remove nozzle and replace
nozzle or the whole assembly.
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III. Fuel distribution injection pump (rotor type injection pump)
1. Injection pipe No.1

5. Injection pump sprocket
6. Injection pump support
7. Injection pump harness assembly
8. Fuel injection pump
9. Fuel pipeline
10. Fuel return pipe nut
11. Fuel return pipe
12. Gasket
13. Nozzle
14. Seat gasket
15. Nozzle gasket
Caution:
Installation sequence is the reverse of removal.
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Rotor distributed type fuel injection pump

Rotor distribution type fuel injection pump (VE type) is rotary single plunger axial compression type fuel
injection pump. Its basic principle is the same as that of gasoline engine ignition distributor. HP fuel outlet pipe is
installed on distributing head fuel outlet valve seat to distribute HP fuel to each cylinder.
This pump consists of driving mechanism, 2-stage blade type fuel transfer pump, distributor, fuel supply advance
angle auto adjustment device, and governor. Structure schematic is as follows:
1-drive shaft; 2-2-stage blade type fuel transfer pump; 3-gear; 4-roller; 5-roller support; 6-fuel supply advance angle auto
adjustment device (90° deployed); 7-disc cam; 8-fuel supply auto regulating lever; 9-distributing rotor spring; 10-fuel
amount control sleeve; 11-fuel relief hole; 12-distributing groove; 13-fuel outlet valve; 14-fuel inlet groove; 15-distributing
sleeve; 16-distributing rotor; 17-fuel cutoff solenoid valve; 18-starting spring; 19-full load regulating screw; 20-calibration
rod; 21-fuel return port; 22-pull rod; 23-governor spring; 24-fly block; 25-control level; 26-regulating valve
1. Driving mechanism
Drive shaft 1 is supported on Al alloy die cast pump casing and rotates at half the rotation speed of engine. This
shaft drives disc cam 7 via a driving disc. This disc cam has the same number of heaved faces as number of engine
cylinders. As driven by the drive shaft, this disc cam relies on roller 4 fixed on roller support 5 for reciprocal
movement according to specified convex surface lift. Rotor knock pin and distributing rotor spring 9 connected on
disc cam perform reciprocal movement with rotation of the disc cam. On 4-cylinder engine, since 4 rollers are
installed on the roller support, and the disc cam has 4 heaving faces, the plunger will perform 4 reciprocal
movements in each round.
2. 2-stage blade type fuel transfer pump
The 2-stage blade type fuel transfer pump is driven by the drive shaft to suck fuel from fuel tank. Then, this fuel
passes oil-water separator and fuel filter to enter the distributor; this section is LP fuel path. Regulating valve 26 is
used to adjust fuel transfer pump output pressure so that it suits rotation speed. Fuel is supplied to fuel injection
pump head at about 250kpa pressure at idling speed, or at 800kpa pressure at 4500rpm.
3. Distributor
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The distributor consists of distributing sleeve 15 that performs fuel metering, compression, distribution and output,
distributing rotor 16 (plunger), fuel amount control sleeve 10 and fuel cutoff solenoid valve 17.
The distributing plunger is press fit in the distributor and includes 1 fuel inlet hole and 4 evenly arranged fuel
outlet holes.
On the distributing rotor, 4 evenly arranged fuel inlet grooves 14, 1 distributing groove 12 and 1 fuel relief hole 11
are provided.
Fuel intake stroke: When the distributing rotor moves left under the action by its return spring, fuel relief holes on
this rotor will be closed by fuel amount control sleeve and the fuel will enter and fill pump cavity from fuel cutoff
solenoid valve and fuel inlet groove; refer to the following figure.
Fuel compression stroke: including decompression zone stroke and effective stroke. When rotor moves right under
the action by roller and disc cam, fuel relief holes on rotor are still closed by fuel amount control sleeve. With
rotor rotation, and obstructed fuel inlet groove and fuel inlet hole, fuel pressure in pump cavity rises quickly.
When this pressure is enough to overcome action of fuel outlet valve spring, this valve will open to supply fuel to
fuel injectors. This section is high pressure fuel path.
Fuel return stroke: During rightward movement of distributing rotor, when fuel relief hole exposes from fuel
amount control sleeve, i.e. facing pump casing, fuel inside distributing rotor will flow toward pump casing. At this
point, fuel compression stroke ends and remaining stroke is fuel return stroke.
During one round rotation of drive shaft, distributing rotor (plunger) performs 4 reciprocal movements and rotates
by 360°. Each of the 4 fuel inlet grooves connects to fuel inlet hole once, the distributing groove is connected to
each of 4 fuel outlet holes once, and each of the 4 fuel outlet valves opens once, i.e. supplying fuel to each of the 4
fuel injectors once.
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Amount of fuel supply is regulated by left and right sliding of fuel amount control sleeve, changing effective
stroke of distributing rotor before fuel relief hole exposes from fuel amount control sleeve, i.e. when this sleeve
moves left, effective stroke is shortened, reducing fuel supply; when the sleeve moves right, effective stroke is
lengthened, increasing fuel supply. Driver controls governor by acceleration pedal so as to change position of this
sleeve, realizing acceleration and deceleration.
The fuel cutoff solenoid valve controls LP fuel path. When ignition switch is at ON position, the solenoid valve is
energized, sucks up to open LP fuel path; when this switch is at OFF position, the solenoid valve is de-energized,
dropping down to close LP fuel path, and stopping the engine.
4. Fuel supply advance angle auto regulating device
As shown in the figure, This device is installed transversely at lower part of distribution pump and consists of
adjusting piston 4, adjusting spring 1, roller support 6 and roller 7 etc. There are 4 rollers 7 on the roller support.
The roller support is connected to adjusting piston via drive pin 2 and connecting pin 3. Piston cylinder left cavity
is connected to fuel inlet via fuel path and its right cavity is connected to pump cavity.
When engine rotation speed rises, drive shaft rotation speed also rises, as well as pressure of fuel transfer pump.
This acts on adjusting piston. When this force exceeds force of adjusting spring, adjusting piston will move in a
direction perpendicular to drive shaft. Therefore, via the drive pin, movement of adjusting piston drives roller
support to rotate in the reverse direction as drive shaft rotation (roller support is not affected by drive shaft
rotation direction), thereby accelerating disc cam lift time and advancing fuel supply.
5. Governor
Rotor distributed type fuel injection pump adopts omnirange mechanic governor (RSV type governor). In this
governor, a set of centrifugal element (fly block), spring and lever mechanism is used to control position of fuel
amount control sleeve, so that the engine can automatically adjust amount of fuel supply under various rotation
speeds.
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6. Supercharging compensator
Since the engine is fitted with turbo-supercharger, a supercharging compensator is installed on top of pump body.
This device is used to limit amount of fuel injection, so as to satisfy strict emission standard.
Supercharging
Air intake
IV. Fuel injection system inspection, removal and installation

Inspection
Fuel injection pump and nozzle on vehicle
In case of defect found, replace injection pump as an assembly.
Caution: Injection pump adjustment is limited to idling speed adjustment.
Description Inspection procedure Standard
Idling operation Measure rotation speed
Exhaust gas color At no-load condition, accelerate engine fast and check color Excessive black smoke not
of exhaust gas (measure smokeness) permitted (smokeness
reference value: within 50%)
Distributor Control accelerator rod to keep engine at about 1500rpm; Change of engine noise
under this condition, manually operate throttle switch button
to observe change of engine rotation speed.
Fuel cutoff valve Turn ignition switch on and off Driving noise (“kata”) heard
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Removal
Fuel injection pipe
When loosening connector nut, use wrench to
clamp injection pump head fuel supply valve seat
or fuel return pipe hex nut to avoid their rotation
along with connector nut.
Caution:
VE type fuel injection pipe is different from
DPC type fuel injection pipe. During
installation, pay attention to this (outer side of
VE type injection pipe is yellow).
Injection pump sprocket

Use special tool to remove injection pump
sprocket.
Caution:
Shaking and vibration of sprocket may cause
fault of injection pump.
Fuel injection pump

When removing fuel loop nut, use wrench to
clamp fuel return pipe by the hex nut.
Caution:
If fuel return pipe is not clamped when
removing hex nut, the pipe may be damaged.
Hence you must clamp fuel return pipe nut
when removing hex nut.
Fuel return pipe nut

When removing fuel return pipe nut, use wrench to
clamp hex nut to prevent moving of fuel return
pipe.
Caution:
If fuel return pipe nut is not clamped when
removing hex nut, the pipe may be damaged.
Hence you must clamp fuel return pipe nut
when removing hex nut.
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Nozzle
Use deep socket wrench to loosen nozzle and
remove it.
Caution:
Mark cylinder No. on removed nozzle. Cover
open parts with suitable cover to prevent dust,
water and foreign matter from entering fuel
pipeline or combustion chamber.
Inspection
Nozzle
Check the following items. If a defect is found,
correct or replace.
Inspection of fuel injection pressure

1. Fit nozzle on nozzle tester and operate tester
handle to vent air from the nozzle.
2. Operate tester handle at about 1 stroke per
second and read value on pressure gauge.
If the reading is lower than maintenance limit,
remove nozzle and replace internal gasket to adjust
so that pressure reading is within standard value
range.
Standard value: 12,000-13,000 kPa
Maintenance limit: 11,000 kPa
Caution:
1) Add 0.1mm shims to increase pressure to
1000kPa;
2) Use 20 shims of thickness 1.00-1.95mm.
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Inspection of fuel beam characteristics

1. Operate tester handle at about 1 stroke per
second. When moving tester handle, injecting
nozzle will generate special intermittent noise
and vibration of needle valve can be felt at the
handle.
Caution:
During fuel injection, some fuel may remain on
spray head. This can be seen when inspecting
nozzle and does not mean fault of nozzle.
2. Fuel beam status
In the figure, only one fuel beam status is good and
all others are not good. The fuel beam shall be
rod-shaped with thick fuel particle. After injection,
fuel vapor exists at spray head. This can be seen
during inspection but does not mean abnormal
state of nozzle.
3. Operate tester handle at 4 to 6 strokes per
second. Fuel beam shape is a cone of about 30
degrees.
Sealing of injection nozzle

Operate nozzle tester to maintain nozzle internal
pressure at 10000-11000kPa (pressure gauge
reading) and check nozzle for fuel leakage.
Installation
Nozzle gasket and nozzle holder gasket
1. Clean cylinder head nozzle holder mounting
plate.
2. Place new nozzle gasket and holder gasket
into cylinder head nozzle holder hole.
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Nozzle
Use deep socket wrench to fit nozzle on cylinder
head and tighten to specified torque.
Fuel return pipe nut

Use wrench to clamp fuel return pipe by the hex
nut; tighten fuel return pipe nut to specified torque.
Fuel injection pipe

When tightening fuel injection pipe nut, use
wrench to clamp fuel supply valve seat or fuel
return pipe by the hex nut to prevent their rotation
with nut.
Adjustment of fuel injection timing

Caution: Cut Timing
Adjust fuel injection timing along with display
matching of engine.
Rotate crankshaft so that No.1 cylinder is at top
dead center of compression stroke.
Crankshaft
pulley
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2. Loosen (but not remove) fuel injection pipe

assembly nuts (total 4 nuts) at injection pump side.
When loosening these nuts, use wrench to clamp
fuel supply valve seat to prevent its rotation with
nut rotation.
3. Loosen the 2 nuts and 2 bolts locking injection
pump, but do not remove them.
4. Remove timing check plug from injection pump

head.
5. Before installing special tool, confirm 10mm

protrusion of push rod. The protrusion part can be
adjusted by an internal nut.
6. Connector special tool (09310-43000) and dial

gauge.
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7. Rotate crankshaft so that notch on sheave is at

about 30º position from No.1 cylinder piston About 300 Set to zero
compression stroke; then set dial gauge to zero.
Lightly rotate crankshaft clockwise and
counterclockwise to confirm dial gauge pointer at
zero position without deviation. If no deviation,
re-adjust sheave position so that the notch is at 30º
before TDC.
8. Rotate crankshaft in normal direction so that its 10.03mm

notch is at 9ºATDC (top dead center) (with fuel
injection timing as reference). Confirm that pointer
reading is within standard value.
Standard value: 1 ± 0.03 mm
9. If pointer reading is not within specified value,

tilt injection pump body left and right till the
reading is within standard value. Then, tighten
injection pump mounting nuts and bolts to
specified torque.
10. Repeat steps 7-8 and check that adjustment is
correct.
11. Remove special tool and dial gauge.
12. Install new copper gasket and timing check
plug. Then tighten plug to specified torque.
13. Tighten fuel injection pipe nut to specified
torque. When tightening, use wrench to clamp fuel
supply valve seat to prevent its rotation along with
nut.
Tightening torque: 23-27 Nm
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Injection nozzle holder
1． Positioning nut
2． Fuel injector nozzle head
3． Washer
4． Locating pin
5． Pressure spring
6． Gasket A:35-40Nm
Note:
Install in the reverse order of removal.
Removal
Set nut
1. Use elastic support to lightly clamp set nut;
2. Use socket wrench to clamp set nut and a
deep socket wrench to loosen nozzle holder.
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Inspection
1. Check nozzle tip for accumulated carbon. Use
wood knife to remove accumulated carbon on
each part. Later, dip the parts in diesel. Pay
special attention to protect nozzle tip needle
valve.
2. While dipping nozzle tip in diesel, check the
needle valve for smooth sliding. If not,
replace nozzle tip. Before using a new nozzle
head, use clean diesel to completely remove
anticorrosion oil on the head.
3. Check plunger head “A” for deform and
breaking. If “A” is damaged or broken,
replace it.
Spacer
Check the surface in contact with nozzle holder.
Pressure spring
Check this spring for softening or breaking.
Re-installation
Set nut
1. Hand tighten nozzle holder.
2. Use gasket to lightly clamp set nut in jaw
vice.
3. Use socket wrench to clamp set nut and use
deep socket wrench to tighten nozzle holder
to specified torque.
Tightening torque: 35-40 Nm
Inspection and adjustment

Idling speed
1. Before inspection and adjustment, set vehicle to the
following status:
● Engine cooling temperature: 80-90℃
● Lights and other accessories: Off
● Transmission position: neutral
2. Check if valve clearance is in standard range.
3. Check if fuel injection timing is in standard range.
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4. Check if idling speed is within standard value.

Standard value: 750±50 rpm
5. If idling speed exceeds standard value, loosen
lock nut of idle adjusting screw and adjust
idling speed to within standard value.
6. After adjustment, fully tighten lock nut.
V. Fuel tank
1． Fuel hose (main) 7. Oil level sensor

2． Oil level sensor connector 8. Oil return hose (main)
3． Fuel filter 9. Fuel hose (connecting)
4． Oil drain plug 10. Oil return hose (main)
5． Fuel filter sleeve 11. Main fuel pipe
6． Fuel filter pump 12. Oil return pipe
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Removal
Fuel filter case
Clamp fuel filter in a jaw vice and use fuel filter
wrench to remove fuel filter case.
Water surface height transducer

Clamp water surface height transducer in a jaw
vice and use hands to rotate and remove fuel filter
case.
Inspection
1. General inspections
1） Check hose and pipeline for cracking, damage,
scratch and clogging.
2） Check fuel filter for clogging and damage.
2. Operation of water surface height transducer
Connect circuit tester to the transducer; when the
float moves up or down, if the circuit is not
conducting or conducting, the transducer is good.
Replacement
Fuel filter
1. Reduce fuel tank pressure by taking down
fuel filter cover.
2. Disconnect water surface height transducer
connector.
3. Use hand to remove fuel filter element from
fuel filter pump body.
4. Disconnect fuel hose (main) from fuel filter
pump.
5. Remove fuel filter pump.
6. Replace fuel filter element.
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Removal of fuel tank
1. Fuel gauge element

2. Breathing hose
3. Fuel tank
4. Oil drain plug
5. Filling/breathing hose assembly
6. Filling hose
7. Breathing hose A:15-22Nm
8. Filling port
9. Filling port cover
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Removal
1. Remove fuel drain plug and drain fuel.
2. Disconnect fuel supply hose and fuel return hose.
3. Disconnect fuel gauge element connector.
4. Disconnect breathing hose and filling hose.
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5. Remove fuel tank; remove fuel gauge element if required.
6. Remove fuel filling port and filling pipe according to the

following procedure.
1）Disconnect filling pipe and breathing hose from filling port
and breathing pipeline.
2）Pull out filling port cover and remove filling port
3）Remove filling pipe and breathing pipe assembly
Installation
When connecting hose to pipeline, note that
overlap length shall be in specified range. Tighten
hose clamp at the position shown in the figure to
prevent interference of hose with other parts.
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VI. Engine control
Accelerator pedal
1. Accelerator pedal assembly

2. Support assembly
3. Return spring
4. Circlip
5. Flat washer
Caution:
The numbers indicate removal sequence. Installation sequence is the reverse.
- 363 -
Throttle control
Re-installation
Accelerator pedal
Apply lubricating grease on accelerator pedal sliding
contact surface.
Return spring
Apply lubricating grease on inner surfaces.
Cable installation and adjustment
Throttle cable
Fully rotate throttle button in the reverse direction
to the arrow marked on button. With inner cable
fully extended, install accelerator pedal or
accelerator rod. Confirm that draw-in bar at fully
extended position when engine speed is lowest.
Caution:
1） Sort each cable so that it is not in contact with metal plate.
2） Path radius of each cable shall be ≥150mm.
- 364 -
Throttle control cable

Rotate throttle button in reverse direction to the
arrow marked on the button and confirm that
accelerator pedal cannot move. Install throttle
control cable on adjusting lever and fix cable at
one side of engine through tightening nut.
Caution:
To install throttle control cable, do not move
engine side adjusting lever.
Accelerator pedal stopper

Adjust so that when engine side adjusting lever
touches fuel stopper, clearance between accelerator
pedal and adjusting bolt is A.
Dimension A: 0-5 mm
- 365 -
VII. Circuit diagram
With current at the ON or START shift
Fuse block
Fuse 15
Detailed diagraph for

the fuses in the
passenger compartment
Throttle
position
sensor Solenoid Solenoid
valve valve
(duty (on/off)
ratio) Fuel cut-off
solenoid
valve
Signal Grounding Solenoid valve Solenoid valve Stored power Preheating

control (duty control (on/off) supply control
ratio) Line L of the module
starting signal Generator
Grounding
See the See the detailed
indicator diagraph for the
data connection
See the
grounding
distribution
Fuel
K line ON/START cut-off
shift
See the See the Input signal solenoid
starting charging valve
system Grounding control
system
(with the
stopping
device)
Water temperature
sensor
- 366 -
Power on at the ON/STAR shift Keep power on
Fuse block Wiring

Fuse 13 Preheater
fuse
Detailed diagraph for the fuses

in the passenger compartment
Instrument
Preheating cluster Preheater relay
light
Speed
controller
Preheating
plug
supply indicator Preheater relay control

control
Grounding
Sensor power Sensor is grounded
Idle speed Speed controller

acceleratio sensor
n control
module
- 367 -

Diesel Engine Fuel Supply System

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Diesel Engine Fuel Supply System

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Ruifeng Commercial Vehicle Maintenance Manual Fuel System (diesel)

Section II Diesel engine fuel supply system

2. Size and parameters

3. Maintenance size and parameters

Fuel injection nozzle

09314-43000 Removal of injection pump sprocket

6. Fuel supply system

Overflow pipe Oil supply pump (air outlet)

Fuel Water level

Oil return pipe

Fault Possible causes Repair

Fault Possible causes Repair

II. Inspection and adjustment

1） Loosen adjusting nut to fully approach

Standard value: about 1 mm

Inspection and adjustment

4. If nozzle is faulty, remove it and adjust

1. If injection is not good, remove nozzle and

Nozzle oil seal

III. Fuel distribution injection pump (rotor type injection pump)

1. Injection pipe No.1

Rotor distributed type fuel injection pump

IV. Fuel injection system inspection, removal and installation

Injection pump sprocket

Fuel injection pump

Fuel return pipe nut

Inspection of fuel injection pressure

Inspection of fuel beam characteristics

Sealing of injection nozzle

Fuel return pipe nut

Fuel injection pipe

Adjustment of fuel injection timing

2. Loosen (but not remove) fuel injection pipe

4. Remove timing check plug from injection pump

5. Before installing special tool, confirm 10mm

6. Connector special tool (09310-43000) and dial

7. Rotate crankshaft so that notch on sheave is at

8. Rotate crankshaft in normal direction so that its 10.03mm

9. If pointer reading is not within specified value,

Tightening torque: 23-27 Nm

Injection nozzle holder

Inspection and adjustment

4. Check if idling speed is within standard value.

1． Fuel hose (main) 7. Oil level sensor

Water surface height transducer

Removal of fuel tank

1. Fuel gauge element

2. Disconnect fuel supply hose and fuel return hose.

3. Disconnect fuel gauge element connector.

4. Disconnect breathing hose and filling hose.

5. Remove fuel tank; remove fuel gauge element if required.

6. Remove fuel filling port and filling pipe according to the

2）Pull out filling port cover and remove filling port

3）Remove filling pipe and breathing pipe assembly

VI. Engine control

1. Accelerator pedal assembly

Cable installation and adjustment

Throttle control cable

Accelerator pedal stopper