Information injection-pump assembly
BOSCH
9 400 610 470
9400610470
ZEXEL
101402-4931
1014024931
Rating:
Service parts 101402-4931 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97134-842-0
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Include in #1:
101402-4931
as INJECTION-PUMP ASSEMBLY
Include in #2:
104739-4020
as _
Cross reference number
BOSCH
9 400 610 470
9400610470
ZEXEL
101402-4931
1014024931
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
131424-4920
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
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
3.2
3.15
3.25
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
A
Rack position
9
Pump speed
r/min
1200
1200
1200
Average injection quantity
mm3/st.
90.5
89.4
91.6
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6+-0.5
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
12
10.6
13.4
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
165
160
170
Fixing the lever
*
Rack limit
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Notch fixed: K
(2)RACK LIMIT
(3)Set idle sub-spring
(4)Main spring setting
----------
K=7
----------
----------
K=7
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(7deg)+-5deg b=(21deg)+-5deg
----------
----------
a=(7deg)+-5deg b=(21deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=4.5deg+-5deg b=53deg+-5deg
----------
----------
a=4.5deg+-5deg b=53deg+-5deg
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=12deg
----------
a=(100deg)
----------
aa=12deg
----------
a=(100deg)
Information:
Install the pump cover onto the pump housing. Tighten the four middle bolts. Then, tighten the end bolts in a crisscross pattern. Tighten the bolts to a torque of 10.2 N m (90 lb in).Note: Make sure that the gasket is in place between the housing and the cover.
Repeat Step 1 and Step 2 in order to confirm the electrical connection for the pump coil was not damaged during the removal of the pump cover.
Install the oil inlet line adapter, inlet line, and harness connector to the pump.Note: After the HEUI pump is replaced or reassembled, the engine must be cranked for an extended length of time to fill the pump with oil.Note: Clear any diagnostic or event codes that activated during the initial start-up.
If the engine would not start before inspecting for debris and no debris was found in the HEUI pump, return to Step D in the diagnostic flow chart.If the engine would start before inspecting for debris and no debris was found in the HEUI pump, return to Step L in the diagnostic flow chart.If the pump is to be replaced, complete the checklist form in Special Instruction, REHS5031 that is provided with the service replacement part and insert the completed form back into the box containing the part that is being returned. Proceed to the section of this instruction titled "Oil Rail Cleaning Procedure" for the correct engine size that is being serviced.Oil Rail Cleaning Procedure For the C7 Engine
Illustration 12 g02702636
C7 Cylinder Head
Illustration 13 g02708256
The oil and fuel passages are the same for both the C7 and C9.
(6) Oil Rail for a HEUI fuel system
(7) Oil passage to injector bore
(8) Fuel passage
(9) Injector bore Note: Contain any oil and cleaner that will flow from the cylinder and the lines during the following process. Properly dispose of the oil and contaminated cleaner when work is complete.
Remove fuel injectors. Refer to Disassembly and Assembly for specific machine.
Install six plugs 9U-7080 Tapered Cap/Plug into the lower injector bores. The plugs will prevent oil, cleaners, and debris from entering the cylinders.
Remove the plugs from the front and rear of the cylinder head main oil gallery
Remove the pressure sensor from the cylinder head. Protect the sensor.
Clean out the two rail drain holes by removing their plugs and using the brake cleaner and long squirting straw to flush these passages to the oil rail.
Using the solvent gun with and without the