| Description and Operation Vehicles Built upto 02/2000 Fuel Injection Pump The engine is equipped with a Bosch VE distributor type fuel injection pump which is driven by the crankshaft via a toothed rubber drive belt. The fuel injection pump is retained to the engine by three bolts at the front and a support bracket at the rear (two bolts). Setting the injection timing is achieved using the familiar peg timing method. The fuel injection pump is fitted with a light load retard device and a cold start advance solenoid, both of which change the natural injection timing characteristics dependent on engine operating conditions. Light Load Retard Device The light load retard device is a mechanical/hydraulic device incorporating a solenoid which is controlled by the powertrain control module (PCM). Under normal operating conditions, and for engine loads up to approximately 80% full load, the device retards the injection timing by approximately 3°. Where engine load is above 80% of full load, engine coolant temperature is below 50°C or engine speed is above 3500 rev/min, the PCM energizes the solenoid which inhibits the operation of the light load retard device, therefore advancing the injection timing. Cold Start Advance Solenoid The cold start advance solenoid is controlled by the PCM. When engine coolant temperature is below 50°C, the PCM energizes the solenoid which advances the injection timing throughout the engine speed/load range. The amount of time which the solenoid is energized decreases as engine coolant temperature increases. The solenoid is also energized when engine coolant temperature is below 0°C and engine speed is just above idle to improve driveability take off. Waxstat A waxstat system is fitted to all vehicles, except those with air conditioning. The waxstat system comprises of a wax element which is located inside the thermostat housing and a control cable which extends from the wax element and connects to the idle lever on the fuel injection pump. When the engine is cold, the cable pulls the idle lever to the high idle position. When the engine is warm, the cable is released allowing the idle lever to return to the normal idle position. Idle Speed Control Motor An idle speed control motor is fitted to all vehicles with air conditioning. The idle speed control motor system comprises of an idle speed control motor which is located under the battery tray and a control cable which extends from the idle speed control motor and connects to the idle lever on the fuel injection pump. Engine idle speed is controlled by the PCM which alters the position of the motor, and therefore, the position of the idle lever. To prevent excess slack in the control cable, the idle speed control motor is fitted with an idle tracking switch which prevents further movement of the motor once the tension on the control cable is released. In addition to giving an increased engine idle speed when the engine is cold, the idle speed control motor system provides accurate idle speed control when the engine is warm, increased idle speed control when the air conditioning is on and/or a low battery voltage condition exists and dashpot engine speed deceleration control. Vehicles Built from 02/2000 Fuel Injection Pump The engine is equipped with a Bosch VP-30 distributor type fuel injection pump. The fuel injection pump is chain driven from the crankshaft and incorporates a pump control unit located on the top of the pump. The pump control unit receives data from the crankshaft position (CKP) sensor and the PCM. The pump control unit calculates the actuation signals for the high-pressure solenoid valve and the fuel injection timing solenoid valve. The pump control unit then controls the fuel delivery through the high-pressure solenoid valve. The fuel injection pump is matched to the PCM and will not allow the vehicle to start if the fuel injection pump control unit and the PCM do not recognize the encrypted codes sent. If a new fuel injection pump or PCM is to be installed they must be configured using WDS. The fuel system incorporates a feature that prevents the fuel system running dry and consequently drawing air into the system. The PCM receives an input signal from the in-tank fuel level sensor. When the fuel in the tank drops to approximately 3 to 4 liters, it will cause a driveability concern alerting the driver of a low fuel concern. The fuel system must be bled when you install a new fuel injection pump. New fuel injection delivery pipes must be installed if they are fully disconnected at either end or removed completely as correct seating cannot be guaranteed if they are reused. All Vehicles Fuel Injectors The engine is equipped with four Bosch fuel injectors which have throttling pintle nozzles. The fuel injectors are screwed into the cylinder head and sealed by means of copper sealing washers. Glow Plugs The engine is equipped with four glow plugs which are screwed into the cylinder head below the fuel injectors. The glow plugs improve starting, especially from cold. The glow plugs and the glow plug indicator lamp are controlled by the PCM. When the ignition is switched on, the glow plugs are switched on and the glow plug indicator lamp is illuminated for between 1 and 10 seconds dependent on engine coolant temperature, (1 second 80°C and 10 seconds at -30°C). The glow plugs remain on for a period of 3 seconds after the glow plug indicator lamp has been extinguished. However, if the engine is started during this 3 second period, the glow plugs will remain on for a further 0 to 40 seconds dependent on engine coolant temperature, (0 seconds at 80°C and 40 seconds at -40°C). | 
