Information injection-pump assembly
ZEXEL
101401-9144
1014019144
Rating:
Service parts 101401-9144 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
TF01 13 H50
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
ZEXEL
101401-9144
1014019144
Zexel num
Bosch num
Firm num
Name
101401-9144
INJECTION-PUMP ASSEMBLY
14BC PE4A,5A, PE
14BC PE4A,5A, PE
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
255
255
Overflow valve opening pressure
kgf/cm2
2.6
2.6
2.6
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 setting
----------
aa=36mm
----------
a=20deg+-5deg b=41deg+-3deg
----------
aa=36mm
----------
a=20deg+-5deg b=41deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)Set the stop adjuster screw
----------
aa=39mm
----------
a=14deg+-5deg b=(29.5deg)+-5deg
----------
aa=39mm
----------
a=14deg+-5deg b=(29.5deg)+-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=4.7+-0.3mm
----------
----------
Na=1825r/min Nb=325r/min Ra=4.7+-0.3mm
----------
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:
9. Remove bracket assembly (16) and link (17). 10. Put identification marks on fuel racks (18) and (19), and remove the fuel racks. 11. Put identification marks on each spacer (20) and lifter (21) so they can be installed in their original position. 12. Remove fuel injection pump camshaft (22) from the pump housing.13. Remove O-ring seal (23). 14. Inspect link pivot shaft (24) and bracket locating pin (25). Make a replacement by removal of shaft (24) and dowel (25) with Tool (D). 15. Inspect upper bearing (26) and the lower bearing that hold the pinion gear in the pump housing.16. Make a replacement of bearings (26) if necessary.17. Inspect idler gear shaft (27). If a replacement is necessary, remove the shaft with Tooling (D). 18. Inspect fuel rack bearings (28) and camshaft bearings (29). If a replacement is necessary, remove bearings (28) and (29).19. Use Tooling (E) to remove bearings (28). 20. Remove regulator valve (30). 21. Remove pin (31) to disassemble the regulator valve, and inspect the components.22. Piston (32) must move freely in valve body (30).23. Make a reference to the Specifications for spring (34).24. Make a replacement of O-ring seals (33).Assemble Fuel Injection Pump Housing
Pin (2) must not extend out of either side of valve body (3).
1. Install spring (4), piston (1) and pin (2) in valve body (3).2. Put clean engine oil on the valve body and O-ring seals (5). Install the oil bypass valve in the pump housing. Tighten the bypass valve body to a torque of 68 14 N m (50 10 lb ft). 3. Install the camshaft front and rear bearings with Tooling (A). Install the front bearing until it is a distance of 1.0 0.5 mm (.04 .02 in) from the front surface of the pump housing. Make sure both oil holes in bearing are in alignment with the oil holes in the pump housing. 4. Put Tool (B) in the fuel pump housing with the dowels of Tool (B) in alignment with the left fuel rack bore. Install the bolt that holds the tool in place on the housing.5. Put a new bearing in position with the tab of the bearing up. Install the bearing with Tool (C) until the shoulder of Tool (C) makes contact with Tool (B).6. Turn Tool (B), and make an alignment of the dowels on Tool (B) with the right fuel rack bore.7. Do Step 3 again for the left fuel rack bearing. 8. Install shaft (6) to a height of 16.8 0.5 mm (.66 .02 in). 9. Make sure the chamfer on the lower bearing for the pinion gear is toward the inside and the notch is in the location shown. Install the bearing 28.4 0.5 mm (1.12 .02 in) below the bearing bore surface with Tooling (D).10. Make sure the chamfer on the upper bearing for the pinion gear is toward the inside and the notch is in the location shown. Use
Pin (2) must not extend out of either side of valve body (3).
1. Install spring (4), piston (1) and pin (2) in valve body (3).2. Put clean engine oil on the valve body and O-ring seals (5). Install the oil bypass valve in the pump housing. Tighten the bypass valve body to a torque of 68 14 N m (50 10 lb ft). 3. Install the camshaft front and rear bearings with Tooling (A). Install the front bearing until it is a distance of 1.0 0.5 mm (.04 .02 in) from the front surface of the pump housing. Make sure both oil holes in bearing are in alignment with the oil holes in the pump housing. 4. Put Tool (B) in the fuel pump housing with the dowels of Tool (B) in alignment with the left fuel rack bore. Install the bolt that holds the tool in place on the housing.5. Put a new bearing in position with the tab of the bearing up. Install the bearing with Tool (C) until the shoulder of Tool (C) makes contact with Tool (B).6. Turn Tool (B), and make an alignment of the dowels on Tool (B) with the right fuel rack bore.7. Do Step 3 again for the left fuel rack bearing. 8. Install shaft (6) to a height of 16.8 0.5 mm (.66 .02 in). 9. Make sure the chamfer on the lower bearing for the pinion gear is toward the inside and the notch is in the location shown. Install the bearing 28.4 0.5 mm (1.12 .02 in) below the bearing bore surface with Tooling (D).10. Make sure the chamfer on the upper bearing for the pinion gear is toward the inside and the notch is in the location shown. Use
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Mazda
101401-9144
INJECTION-PUMP ASSEMBLY