101401-9217 ZEXEL 9 400 613 797 BOSCH INJECTION-PUMP ASSEMBLY 9400613797 1014019217 tmsk13800g


 

Information injection-pump assembly

BOSCH 9 400 613 797 9400613797
ZEXEL 101401-9217 1014019217
MAZDA TMSK13800G tmsk13800g
101401-9217 INJECTION-PUMP ASSEMBLY
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Service parts 101401-9217 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101041-9290
3. GOVERNOR 105921-6815
4. SUPPLY PUMP 105210-6350
5. AUTOM. ADVANCE MECHANIS 105671-0400
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105118-5481
11. Nozzle and Holder TM01 13 H50
12. Open Pre:MPa(Kqf/cm2) 19.6{200}
13. NOZZLE-HOLDER 105048-3781
14. NOZZLE 105017-1360
15. NOZZLE SET

Include in #1:

101401-9217 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 613 797 9400613797
ZEXEL 101401-9217 1014019217
MAZDA TMSK13800G tmsk13800g


Zexel num
Bosch num
Firm num
Name
101401-9217 
9 400 613 797 
TMSK13800G  MAZDA
INJECTION-PUMP ASSEMBLY
TM K 14BC INJECTION PUMP ASSY PE4A,5A, PE

Calibration Data:

Adjustment conditions
Test oil
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
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
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right
  R
Injection order   1-3-4-2
Pre-stroke mm   3.2 3.15 3.25
Beginning of injection position
Drive side
  NO.1
Difference between angles 1
Cal 1-3
deg.   90 89.5 90.5
Difference between angles 2
Cal 1-4
deg.   180 179.5 180.5
Difference between angles 3
Cyl.1-2
deg.   270 269.5 270.5
Injection quantity adjustment
Adjusting point   -
Rack position   11.7
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   62 61.5 62.5
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   425 425 425
Average injection quantity mm3/st.   10.5 8.5 12.5
Max. variation between cylinders %   0 -14 14
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(11.7)
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   62 61.5 62.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.65
Pump speed r/min   450 450 450
Average injection quantity mm3/st.   51.5 47.5 55.5
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   I
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   98 98 113
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   850--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   800
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1100
Advance angle deg.   1.5 1 2
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101401-9217
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=J02
----------

Speed control lever angle

Test data 101401-9217
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=36mm
----------
a=15deg+-5deg b=(36deg)+-3deg

Stop lever angle

Test data 101401-9217
N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=39mm
----------
a=40deg+-5deg b=36.5deg+-5deg

Timing setting

Test data 101401-9217
(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)




Information:

5N5930 Fuel Injection Lines Group
(1) Remove former fuel injection lines (1) from each fuel injection pump to the adapters in the base of the valve mechanism cover. Remove the cover from the base. Remove the through-the-base adapter for each set of fuel lines. Put an 8M4437 Seal on each 1W6777 Adapter (2) and install the adapters in each bore where the adapters were removed. Use engine oil as a lubricant on the seals. Fasten the adapters to the cover base with the former nuts and two 5N5365 Locks on each. Connect former fuel lines (3) to adapters (2) and to the injector nozzles. (2) Install 2W2496 Bracket (4) and 2W2495 Bracket (5) where the former brackets were removed. Put a 5P9267 Seal on each injector pump and put a 2W2500 Washer (6) and 6V6579 Seal (7) on each adapter (2). Loosely install the fuel injection line assemblies that follow: 1W6318 (8), 1W6316 (9), 1W6313 (10), 1W6317 (11), 1W6315 (12), 1W6312 (13), 1W6314 (14) and 1W6311 (15). Tighten fuel injection line nuts (16) on each fuel line to 41 7 N m (30 5 lb.ft.) before cover nuts (17) are tightened. If the fuel lines have metal tags for part number identification, remove the tags before installation. Fasten tubes (8), (9), (12) and (15) together on the left side with four 2W2492 Clamps (18), 2W2493 Clamps and 310216 Bolts. Fasten the fuel lines to brackets (4) and (5) with 2W2492 Clamps (19), 2W2493 Clamps, 2W2494 Spacers, 1D4533 Bolts and 3B4504 Lockwashers. Fasten the fuel injection lines together on the right side with 2W2492 Clamps (20), 2W2493 Clamps and 310216 Bolts. Install four 2W2498 and 2W2499 Clamps on tubes (12) and (14) with 6V5370 Screws as shown.2W1788 Fuel Lines Drain Group
(1) Install a 9L8496 Tee (1) on each fuel line adapter (2). Install six 5N5940 Tube Assemblies (3) between tees (1) as shown. Install two 9L8492 Plugs (4). Install 2W3092 Tube Assembly (5), 2W3091 Tube Assembly (6) and 9L8557 Tee (7). Install 4M5317 Bushing (8) and 8B1931 Bushing (9) in 2N9768 Switch (10). Install 9L8496 Tee (11) in bushing (9). Fasten switch (10) to 2W3089 Bracket Assembly (12) with two S1616 Bolts, four 5P537 Washers and two 9S8750 Nuts. Fasten bracket (12) to the side of the engine with two S1594 Bolts, 5M2894 Washers and 9S8752 Nuts. Connect 2W3935 Tube Assembly (13) to tees (7) and (11). Install a 9L8492 Plug in the other side of tee (11). Install 5K9243 Elbow (14) in bushing (8). Connect 5N7739 Tube Assembly (15) to elbow (14). Fasten tubes (13) and (15) to existing bolts with 2B2404 Clips (16).

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