Information injection-pump assembly
ZEXEL
101401-9002
1014019002
MAZDA
TF0113800
tf0113800
Rating:
Cross reference number
ZEXEL
101401-9002
1014019002
MAZDA
TF0113800
tf0113800
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
105780-8140
Bosch type code
EF8511/9A
Nozzle
105780-0000
Bosch type code
DN12SD12T
Nozzle holder
105780-2080
Bosch type code
EF8511/9
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
131424-3420
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
Tester oil delivery pressure
kPa
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
Direction of rotation (viewed from drive side)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-3-4-2
Pre-stroke
mm
3.3
3.25
3.35
Beginning of injection position
Drive side NO.1
Drive 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
12.8
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
70.5
70
71
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
9.5+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
9
7
11
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(12.8)
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
70.5
70
71
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.5
Pump speed
r/min
1625
1625
1625
Average injection quantity
mm3/st.
84.1
80.1
88.1
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.5
Pump speed
r/min
625
625
625
Average injection quantity
mm3/st.
49.6
45.6
53.6
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
160
160
Fixing the lever
*
Timer adjustment
Pump speed
r/min
700
Advance angle
deg.
0.3
Timer adjustment_02
Pump speed
r/min
1300
Advance angle
deg.
2
2
2.5
Timer adjustment_03
Pump speed
r/min
1600-25
Advance angle
deg.
5
4.5
5
Remarks
Finish
Finish
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.
----------
T1=D71
----------
----------
T1=D71
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=36mm
----------
a=20deg+-5deg b=41deg+-3deg
----------
aa=36mm
----------
a=20deg+-5deg b=41deg+-3deg
Stop lever angle
N:Pump normal
S:Engine stop
(1)Use the hole at R = aa
(2)Set the stop adjuster screw
----------
aa=39mm
----------
a=14deg+-5deg b=26deg+-5deg
----------
aa=39mm
----------
a=14deg+-5deg b=26deg+-5deg
0000001501 LEVER
CL:Center line of camshaft
ST:Stop adjuster screw
f1:Direction for pulling the speed lever
f2:Direction for pulling the stop lever
1. Stop lever adjustment outline
(1)After completing all adjustments, confirm that the lever angle is within the specifications in the normal position.
(2)Set the speed lever in the full speed position.
(3)At pump speed Na, position the rack at non-injection position Ra.
(4)Set the stop adjusting screw to fix the speed lever in the idling position.
(5)Confirm that there is no injection at pump speed Nb.
----------
Na=1825r/min Nb=325r/min Ra=6.5-0.5mm
----------
----------
Na=1825r/min Nb=325r/min Ra=6.5-0.5mm
----------
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=9deg
----------
a=(140deg)
----------
aa=9deg
----------
a=(140deg)
Information:
Start By:a. remove flywheel housing 1. Loosen four bolts (1) approximately 6.4 mm (.25 in). Use Tool (A) to loosen camshaft rear gear (2) from the camshaft.2. Remove Tool (A) and four bolts (1).
If balancer gear (3) is in a position similar to that shown in the picture, the weight on balancer gear (3) will turn down when the camshaft rear gear is removed. To prevent personal injury, hold balancer gear (3) when camshaft rear gear (2) is removed.
3. Remove camshaft rear gear (2). 4. Remove bolt (4), plate (5) and balancer gear (3).5. Inspect the bearing in balancer gear (3). The inside diameter (bore) of a new bearing must be 50.853 to 50.950 mm (2.0021 to 2.0059 in). 6. Use Tooling (B) and a press to remove the bearing from balancer gear (3). 7. Inspect shaft (7) for wear or damage. The outside diameter (new) of shaft (7) must be 50.787 to 50.813 mm (1.9995 to 2.0005 in).8. If a replacement of shaft (7) is necessary, remove bolts (6) and shaft (7) from the cylinder block.Install Camshaft Rear Gear & Balancer
1. Install shaft (7) and four bolts (6) on the cylinder block. 2. Use Tooling (A) to install the bearing in balancer gear (3). Install the bearing so that the bearing joint is on the weight side of the gear within 20 degrees of the centerline as shown. Install the bearing so that it is 1.3 mm (.05 in) from the opposite surface on balancer gear (3). 3. Put clean engine oil on the inside diameter of the bearing in the balancer gear. Install balancer gear (3) and plate (5). Make sure the side of the balancer gear with the weight is toward the cylinder block. Install the bolt (4) that holds the balancer gear in position on the shaft. Check to make sure that there is 0.15 to 0.36 mm (.006 to .014 in) end play between the balancer gear and the shaft.
Be sure the timing "V" marks (8) are aligned when the camshaft rear gear is installed on the camshaft.
4. Engage camshaft rear gear (2) with the dowel on the camshaft. Install bolts (1).5. Tighten bolts (1) to a torque of 23 to 31 N m (17 to 23 lb ft).End By:a. install flywheel housing
If balancer gear (3) is in a position similar to that shown in the picture, the weight on balancer gear (3) will turn down when the camshaft rear gear is removed. To prevent personal injury, hold balancer gear (3) when camshaft rear gear (2) is removed.
3. Remove camshaft rear gear (2). 4. Remove bolt (4), plate (5) and balancer gear (3).5. Inspect the bearing in balancer gear (3). The inside diameter (bore) of a new bearing must be 50.853 to 50.950 mm (2.0021 to 2.0059 in). 6. Use Tooling (B) and a press to remove the bearing from balancer gear (3). 7. Inspect shaft (7) for wear or damage. The outside diameter (new) of shaft (7) must be 50.787 to 50.813 mm (1.9995 to 2.0005 in).8. If a replacement of shaft (7) is necessary, remove bolts (6) and shaft (7) from the cylinder block.Install Camshaft Rear Gear & Balancer
1. Install shaft (7) and four bolts (6) on the cylinder block. 2. Use Tooling (A) to install the bearing in balancer gear (3). Install the bearing so that the bearing joint is on the weight side of the gear within 20 degrees of the centerline as shown. Install the bearing so that it is 1.3 mm (.05 in) from the opposite surface on balancer gear (3). 3. Put clean engine oil on the inside diameter of the bearing in the balancer gear. Install balancer gear (3) and plate (5). Make sure the side of the balancer gear with the weight is toward the cylinder block. Install the bolt (4) that holds the balancer gear in position on the shaft. Check to make sure that there is 0.15 to 0.36 mm (.006 to .014 in) end play between the balancer gear and the shaft.
Be sure the timing "V" marks (8) are aligned when the camshaft rear gear is installed on the camshaft.
4. Engage camshaft rear gear (2) with the dowel on the camshaft. Install bolts (1).5. Tighten bolts (1) to a torque of 23 to 31 N m (17 to 23 lb ft).End By:a. install flywheel housing