Information injection-pump assembly
BOSCH
F 01G 09U 00Y
f01g09u00y
ZEXEL
101401-7294
1014017294

Rating:
Service parts 101401-7294 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97115-503-1
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/21.6{220}
14.
NOZZLE
Cross reference number
BOSCH
F 01G 09U 00Y
f01g09u00y
ZEXEL
101401-7294
1014017294
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
1404 Test oil ISO4113 or {SAEJ967d}
Test oil temperature
degC
40
40
45
Nozzle and nozzle holder
105780-8250
Bosch type code
1 688 901 101
Nozzle
105780-0120
Bosch type code
1 688 901 990
Nozzle holder
105780-2190
Opening pressure
MPa
20.7
Opening pressure
kgf/cm2
211
Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
134424-3920
Overflow valve opening pressure
kPa
127
107
147
Overflow valve opening pressure
kgf/cm2
1.3
1.1
1.5
Tester oil delivery pressure
kPa
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
Direction of rotation (viewed from drive side)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-3-4-2
Pre-stroke
mm
3.8
3.75
3.85
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
-
Rack position
13.1
Pump speed
r/min
1160
1160
1160
Average injection quantity
mm3/st.
97
95.4
98.6
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
9.8+-0.5
Pump speed
r/min
290
290
290
Average injection quantity
mm3/st.
14.5
13.2
15.8
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(13.1)
Pump speed
r/min
1160
1160
1160
Average injection quantity
mm3/st.
97
96
98
Basic
*
Fixing the lever
*
Boost pressure
kPa
60
60
Boost pressure
mmHg
450
450
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.35
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
96.5
92.5
100.5
Fixing the lever
*
Boost pressure
kPa
60
60
Boost pressure
mmHg
450
450
Injection quantity adjustment_05
Adjusting point
C
Rack position
R2-0.45
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
86
82
90
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
95
95
127
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
700
700
700
Rack position
R2-0.45
Boost pressure
kPa
27.3
26
28.6
Boost pressure
mmHg
205
195
215
Boost compensator adjustment_02
Pump speed
r/min
700
700
700
Rack position
R2(R1-0.
6)
Boost pressure
kPa
46.7
46.7
46.7
Boost pressure
mmHg
350
350
350
Timer adjustment
Pump speed
r/min
1185--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1135
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1450
Advance angle
deg.
4.8
4.3
5.3
Timer adjustment_04
Pump speed
r/min
-
Advance angle
deg.
5
4.5
5.5
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment

N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Boost compensator stroke: BCL
----------
T1=K06 BCL=0.45+-0.1mm
----------
----------
T1=K06 BCL=0.45+-0.1mm
----------
Speed control lever angle

F:Full speed
I:Idle
(1)Stopper bolt set position 'H' (rack position = aa, speed = bb)
----------
aa=(9.7)mm bb=310r/min
----------
a=40deg+-5deg b=(39deg)+-3deg
----------
aa=(9.7)mm bb=310r/min
----------
a=40deg+-5deg b=(39deg)+-3deg
Stop lever angle

N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
----------
aa=64mm
----------
a=20deg+-5deg b=29deg+-5deg
----------
aa=64mm
----------
a=20deg+-5deg b=29deg+-5deg
0000001501 FICD

(A) applied negative pressure
(B) Screw
(c) Nut
1. Set the actuator as described below.
(1)Confirm that there is clearance between the actuator lever and the speed lever.
(2)Loosen the nut (C).
(3)Push in the screw (B).
(4)Apply P1 from the actuator (A) part.
(5)Pull out the screw (B) slowly.
(6)Tighten and fix the nut (C) when pump speed is Na and the rack position is Ra.
(7)Torque the nut (C) to T1.
(8)Apply P2 several times.
(9)Confirm that the actuator functions normally.
(10)Confirm that there is a clearance between the actuator lever and the speed lever at that time.
----------
P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) Na=425r/min Ra=9.1+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(5)mm
----------
P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) Na=425r/min Ra=9.1+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(5)mm
Timing setting

(1)Pump vertical direction
(2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection
(3)Timing device stamping
(4)At the No 1 cylinder's beginning of injection, align with the aligning mark seen through the bracket's check hole and mark the A/T's bevel C1.
(5)B.T.D.C.: aa
----------
aa=7deg
----------
a=(60deg) b=(85deg)
----------
aa=7deg
----------
a=(60deg) b=(85deg)
Information:
Liner Projection Check
(1) 1P2402 Gauge Body. (2) 1P2403 Dial Indicator.3. Use body (1) and dial indicator (2) assembly to measure the cylinder liner (flange) projection in four locations around the liner. Do not measure liner projection from the flame ring (if equipped). Projection must be 0.10 mm (.004 in) above to 0.10 mm (.004 in) below the cylinder block face. The four measurements should not vary more than 0.03 mm (.001 in). The average projection between adjacent cylinders must not vary more than 0.03 mm (.001 in)Connecting Rods And Pistons
1. On T4.236 Engines, install the piston cooling jets and tighten the banjo bolt to 25 N m (20 lb ft). Adjust the piston cooling jets if necessary. See Piston Cooling Jet Position Check (T4.236 Engines) in Testing And Adjusting.2. Put a liberal amount of clean engine oil on the crankshaft journals, main bearings and thrust washers. Put the upper half of the main bearings and the crankshaft in position in the cylinder block.3. Slide the upper thrust washer halves into the recesses provided on either side of the center main bearing housing.4. Install the lower half of the main bearings into the main bearing caps. Install the main bearing caps to their respective positions. Position the lower thrust washer halves on either side of the center main bearing cap.5. The main bearing caps are numbered 1 through 5, beginning at the front of the block. Each cap is also marked with a serial number which is also stamped on the cylinder block bottom face. They all should read the same way.6. Install and tighten the main bearing bolts and tighten to a torque of 247 N m (180 lb ft).Use the 1Y7426 Piston Ring Compressor to remove or install piston rings.7. Put a liberal amount of clean engine oil in the bore of each cylinder and on the pistons before they are installed.8. Install the piston and connecting rod assemblies using the piston ring compressor as a guide. Be sure the piston and rod number are the same as for the cylinder bore each is installed in. The rod identification number must be opposite the camshaft. The word "Front" or arrow marked on the piston crown must be toward the front of the engine. If the piston crown is not marked, put the offset (narrowest distance between hole and edge of piston) of the piston toward the fuel injection pump side of the block.The connecting rod bearings must fit tightly in the bore of the rod. If bearing joints or backs are worn (fretted), check for bore size as this is an indication of wear because of looseness. Install the bearing cap with the numbers on the same side of the rod and cap.9. Install the connecting rod bolts so the flat on the bolt head is against the shoulder of the rod. Install new rod nuts. Tighten rod nuts to the torque that follows: Cadmium plated nuts silver color) ... 100 N m (75 lb ft)Phosphated nuts