Information injection-pump assembly
BOSCH
9 400 610 486
9400610486
ZEXEL
101402-7201
1014027201
ISUZU
8971710371
8971710371
Rating:
Service parts 101402-7201 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97079-653-0
12.
Open Pre:MPa(Kqf/cm2)
14.7{150}
15.
NOZZLE SET
Include in #1:
101402-7201
as INJECTION-PUMP ASSEMBLY
Include in #2:
104207-1000
as _
Cross reference number
BOSCH
9 400 610 486
9400610486
ZEXEL
101402-7201
1014027201
ISUZU
8971710371
8971710371
Zexel num
Bosch num
Firm num
Name
101402-7201
9 400 610 486
8971710371 ISUZU
INJECTION-PUMP ASSEMBLY
4JG2 K 14BC INJECTION PUMP ASSY PE4A,5A, PE
4JG2 K 14BC INJECTION PUMP ASSY 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
131424-0820
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)
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
2.25
2.2
2.3
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
9.4
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
43.3
42.3
44.3
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
8.8+-0.5
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
17.3
15.3
19.3
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Set idle sub-spring
(4)Main spring setting
----------
K=14
----------
----------
K=14
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Set the pump speed at aa
(2)Set the pump speed at bb.
(3)Stopper bolt setting
(4)Stopper bolt setting
----------
aa=750r/min bb=900r/min
----------
a=(6deg)+-5deg b=(12deg)+-5deg c=(5deg)+-5deg
----------
aa=750r/min bb=900r/min
----------
a=(6deg)+-5deg b=(12deg)+-5deg c=(5deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)No return spring
----------
----------
a=66.5deg+-5deg b=53deg+-5deg
----------
----------
a=66.5deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'W' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=14deg
----------
a=(210deg)
----------
aa=14deg
----------
a=(210deg)
Information:
start by:a) remove valve covers and bases 1. Use tool (A) to loosen the nuts on the fuel injection valves and use tool (B) to loosen the nuts on the adapter assemblies in the cylinder head. Remove inner fuel lines (1).
If necessary, use tooling (D) to turn the engine so the valves do not make contact with the pistons when the valves are opened with tool (C) to remove the push rods.
2. Put compression on the valve springs with tool (C) and remove push rods (2).3. Push the push rod end of the rocker arms down. 4. Remove the intake valve lifter with tooling (E) as follows: a) Install the 5P2685 Nut and the 5P6601 Collet on the 5P2408 Outer Handle Assembly.b) Install the 5P6599 Inner Handle Assembly in the 5P2408 Outer Handle Assembly.c) Install tooling (E) in the intake valve lifter. Hold the 5P2408 Outer Handle Assembly and tighten the 5P6599 Inner Handle Assembly until the 5P6601 Collet is tight against the inside of intake valve lifter. d) Remove intake valve lifters (3) from the cylinder block with tooling (E). 4. Remove the exhaust valve lifters with tooling (E) as follows: a) Install 5P2685 Nut (5) and 5P6601 Collet (6) on 5P2408 Outer Handle Assembly (4). The opening in the cylinder head for the intake valve lifter is larger than the opening in the exhaust valve lifter side. The tooling and each valve lifter must be installed and removed from the intake valve lifter side. b) Install the outer handle assembly in the intake valve lifter side of the cylinder head. Slide the flat area of 5P2408 Outer Handle Assembly (4) through the head casting and install the 5P6601 Collet in the exhaust valve lifter. c) Install 5P6599 Inner Handle Assembly (7) in 5P2408 Outer Handle Assembly (4). Hold the 5P2408 Handle Assembly and tighten the 5P6599 Handle Assembly until the 5P6601 Collet is tight against the inside of exhaust valve lifter.d) Pull the exhaust valve lifter up until the spring on the exhaust valve lifter is free from the cylinder block.e) Remove the 5P6599 Inner Handle Assembly. Slide the 5P2408 Outer Handle Assembly through the head casting and remove it from the intake valve lifter side of the cylinder head. f) Use a magnet and remove exhaust valve lifter (8) from the intake valve lifter side of the cylinder head.5. Remove the guide springs from the lifters.Install Valve Lifters
Steps 1 and 2 must be done to install intake or exhaust valve lifters.
When a valve lifter is removed, a new guide spring must be installed.
1. Install a new guide spring (1) on the valve lifters. 2. Put the intake or exhaust valve lifter in position in 5P2395 Holder (5) of tooling (A). Install 5P2685 Nut (4) and 5P2400 Compressor (3) on 5P2408 Outer Handle Assembly (2). Install the 5P2400 Compressor on the lifter over the guide spring. The opening in the cylinder head for the intake valve lifter is larger than the opening in the exhaust valve
If necessary, use tooling (D) to turn the engine so the valves do not make contact with the pistons when the valves are opened with tool (C) to remove the push rods.
2. Put compression on the valve springs with tool (C) and remove push rods (2).3. Push the push rod end of the rocker arms down. 4. Remove the intake valve lifter with tooling (E) as follows: a) Install the 5P2685 Nut and the 5P6601 Collet on the 5P2408 Outer Handle Assembly.b) Install the 5P6599 Inner Handle Assembly in the 5P2408 Outer Handle Assembly.c) Install tooling (E) in the intake valve lifter. Hold the 5P2408 Outer Handle Assembly and tighten the 5P6599 Inner Handle Assembly until the 5P6601 Collet is tight against the inside of intake valve lifter. d) Remove intake valve lifters (3) from the cylinder block with tooling (E). 4. Remove the exhaust valve lifters with tooling (E) as follows: a) Install 5P2685 Nut (5) and 5P6601 Collet (6) on 5P2408 Outer Handle Assembly (4). The opening in the cylinder head for the intake valve lifter is larger than the opening in the exhaust valve lifter side. The tooling and each valve lifter must be installed and removed from the intake valve lifter side. b) Install the outer handle assembly in the intake valve lifter side of the cylinder head. Slide the flat area of 5P2408 Outer Handle Assembly (4) through the head casting and install the 5P6601 Collet in the exhaust valve lifter. c) Install 5P6599 Inner Handle Assembly (7) in 5P2408 Outer Handle Assembly (4). Hold the 5P2408 Handle Assembly and tighten the 5P6599 Handle Assembly until the 5P6601 Collet is tight against the inside of exhaust valve lifter.d) Pull the exhaust valve lifter up until the spring on the exhaust valve lifter is free from the cylinder block.e) Remove the 5P6599 Inner Handle Assembly. Slide the 5P2408 Outer Handle Assembly through the head casting and remove it from the intake valve lifter side of the cylinder head. f) Use a magnet and remove exhaust valve lifter (8) from the intake valve lifter side of the cylinder head.5. Remove the guide springs from the lifters.Install Valve Lifters
Steps 1 and 2 must be done to install intake or exhaust valve lifters.
When a valve lifter is removed, a new guide spring must be installed.
1. Install a new guide spring (1) on the valve lifters. 2. Put the intake or exhaust valve lifter in position in 5P2395 Holder (5) of tooling (A). Install 5P2685 Nut (4) and 5P2400 Compressor (3) on 5P2408 Outer Handle Assembly (2). Install the 5P2400 Compressor on the lifter over the guide spring. The opening in the cylinder head for the intake valve lifter is larger than the opening in the exhaust valve
Have questions with 101402-7201?
Group cross 101402-7201 ZEXEL
Isuzu
101402-7201
9 400 610 486
8971710371
INJECTION-PUMP ASSEMBLY
4JG2
4JG2