Electronic Fuel Injection Systems Manual Table of Content

Group 00—Safety . . . . . . . . . . . . . . . . . . . 00-1
Group 02—General Information
About This Manual . . . . . . . . . . . . . . . . . . . 02-1
Engine Controller Serial Number Plate . . . . . . 02-1
Injection Pump Serial Number Plate . . . . . . . 02-2
Glossary of Terms . . . . . . . . . . . . . . . . . . . 02-3
System Power Requirements . . . . . . . . . . . . 02-5
Engine Controller Environmental
Restrictions . . . . . . . . . . . . . . . . . . . . . . 02-5
Electrical Concepts . . . . . . . . . . . . . . . . . . . 02-5
Using a Digital Multimeter . . . . . . . . . . . . . . 02-6
Use of a Diagnostic Reader . . . . . . . . . . . . . 02-8
Group 05—Fuel Injection System Components
Major System Components . . . . . . . . . . . . . 05-1
Engine Controller . . . . . . . . . . . . . . . . . . . . 05-1
Robert Bosch Injection Pump/Actuator
Assembly . . . . . . . . . . . . . . . . . . . . . . . . 05-2
Nippondenso Injection Pump/Actuator
Assembly . . . . . . . . . . . . . . . . . . . . . . . . 05-5
Auxiliary Speed Sensor . . . . . . . . . . . . . . . . 05-7
Transient Voltage Protection Module
(TVP) . . . . . . . . . . . . . . . . . . . . . . . . . . 05-8
Group 10—Basic System and Diagnostic Features
How The Electronically-Controlled Fuel Injection System Works
Description . . . . . . . . . . . . . . . . . . . . . . . 10-1
Operation . . . . . . . . . . . . . . . . . . . . . . . 10-2
Self-Diagnosis and Back-Up Features . . . . . . 10-2
Fault Lamp Operation . . . . . . . . . . . . . . . . . 10-3
Governor Modes . . . . . . . . . . . . . . . . . . . . 10-4
Starting Control . . . . . . . . . . . . . . . . . . . . . 10-5
Maximum Fuel Quantity Control . . . . . . . . . . 10-6
Smoke Control . . . . . . . . . . . . . . . . . . . . . 10-7
Fuel Temperature Compensation . . . . . . . . . 10-7
Fuel Flow/Throttle Output Signal . . . . . . . . . . 10-8
Auxiliary Speed Output Signal . . . . . . . . . . . 10-8
Understanding the Throttle Options . . . . . . . . 10-9
Diagnostic Codes Operation . . . . . . . . . . . . 10-11
Using the Electronic Governor
Tester—JT05829 . . . . . . . . . . . . . . . . . . 10-13
Listing of Diagnostic Codes . . . . . . . . . . . . 10-16
Group 15—Robert Bosch Fuel System Connectors
Engine Controller Connector (X1) . . . . . . . . . 15-1
Auxiliary Speed Sensor Connector (X2) . . . . . 15-4
Fuel Shut-Off Solenoid Connector (X11) . . . . 15-5
Actuator Connector (X12) . . . . . . . . . . . . . . 15-6
Fuel Temperature Sensor Connector
(X13) . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
In-Line Connectors (X7, X8, X9, X10) . . . . . . 15-7
Service Connectors (X3, X4, X5, X6) . . . . . . . 15-8
Using the Diagnostic Voltages Connector
(X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-8
Using the Diagnostic Reader Connector
(X4) . . . . . . . . . . . . . . . . . . . . . . . . . . 15-12
Group 20—Nippondenso Fuel System Connectors
Engine Controller Connector (X1) . . . . . . . . . 20-1
Auxiliary Speed Sensor Connector (X2) . . . . . 20-4
Fuel Shut-Off Solenoid Connector (X10) . . . . 20-4
Actuator Connectors (X7, X9) . . . . . . . . . . . . 20-5
Fuel Temperature Sensor Connector (X8) . . . . 20-6
Service Connector—X3, X4, X5 . . . . . . . . . . 20-7
Using the Diagnostic Voltages Connector
(X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-7
Using the Diagnostic Reader Connector
(X4) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11
Group 25—Robert Bosch Fuel Injection System Diagnostic Procedures
How to Start Troubleshooting a Problem . . . . 25-1
Troubleshooting Tools Needed . . . . . . . . . . . 25-2
Troubleshooting Suggestions . . . . . . . . . . . . 25-2
Initial Operational Checks . . . . . . . . . . . . . . 25-6
Symptom-Only Procedures . . . . . . . . . . . . 25-11