101402-7681 ZEXEL 9 400 613 978 BOSCH INJECTION-PUMP ASSEMBLY 9400613978 1014027681 8972393730

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 978 9400613978

ZEXEL 101402-7681 1014027681

ISUZU 8972393730 8972393730

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Buy INJECTION-PUMP ASSEMBLY 101402-7681 zexel genuine, new aftermarket engine parts with delivery

Service parts 101402-7681 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8930

3. GOVERNOR 105419-4110

4. SUPPLY PUMP 105220-7300

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156643-3120

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4480

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 18.1(185)

13. NOZZLE-HOLDER 105030-4750

14. NOZZLE

105025-0290

15. NOZZLE SET

Include in #1:

101402-7681 as INJECTION-PUMP ASSEMBLY

106672-9870 as _

Cross reference number

BOSCH 9 400 613 978 9400613978

ZEXEL 101402-7681 1014027681

ISUZU 8972393730 8972393730

Zexel num

Bosch num

Firm num

Name

101402-7681

9 400 613 978

8972393730 ISUZU

INJECTION-PUMP ASSEMBLY
4BG1-T 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 131424-4920

Overflow valve opening pressure kPa 127 127 127

Overflow valve opening pressure kgf/cm2 1.3 1.3 1.3

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 A

Rack position 8.8

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 83.5 82.4 84.6

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 475 475 475

Average injection quantity mm3/st. 8.8 7.4 10.2

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. 125 120 130

Fixing the lever *

Rack limit *

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)RACK LIMIT (4)Set idle sub-spring
----------
K=6
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=1deg+-5deg b=20deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal
----------

----------
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=14deg
----------
a=(100deg)

Information:

Camshaft
When reconditioning an engine, check the diameter of the camshaft bearing journals and the camshaft lobe height.Camshaft bearing journals have a diameter of 2.5000 .0005 in. (63.500 0.013) and the minimum diameter worn is 2.4970 in. (63.424 mm).To measure height (B) of camshaft lobes, use the following procedures: 1. Measure base circle (C) of one exhaust and one intake lobe. Make a record of each dimension.2. Add lobe lift dimension (A) to each base circle measurement. The lobe lift dimension (A) is .3071 in. (7.800 mm) for the exhaust lobe and .3077 in. (7.816 mm) for the intake lobe.3. The minimum height of lobe (B) is .025 in. (0.64 mm) less than the dimension found in Step 2.Example of finding the height of a lobe:Base circle (C) ... 1.8200 in.(46.228 mm)Add lobe lift (A) ... .3077 in.(7.816 mm)Lobe height (B) ... 2.1277 in.(54.044 mm)Maximum wear of lobe ... .025 in.(0.64 mm)Minimum height of lobe ... 2.1027 in.(53.409 mm)
CAMSHAFT LOBE
A. Lobe lift. B. Lobe height. C. Base circle.With camshaft installed in the cylinder block, check end play. End play with new components should be .007 .003 in. (0.18 0.08 mm). The maximum permissible end play is .020 in. (0.51 mm).Camshaft Followers
Use an 8S2293 Magnet to remove the cam followers.
REMOVING CAM FOLLOWERSCam followers establish a wear pattern with the camshaft lobes. Identify and reinstall the followers in the same location from which they were removed. Dishing or circular wear pattern is allowed on the cam follower face, providing the wear face keeps a polished appearance. Replace the follower if the wear face is rough or shows signs of scuffing. A new follower can be used with an old camshaft, providing the lobe is in good condition. Put engine oil on the cam followers and the camshaft lobes before installing the cam followers. Use new cam followers with a new camshaft.Camshaft Gears
1100 and 3100 Engines With Fuel Pump Camshaft Mounted Timing Advance
1. Use a 1P2320 Puller to remove the camshaft small outer gear.
PULLING SMALL GEAR (Typical Example)2. Remove the spacer immediately behind the gear.3. Use a 1P2321 Puller to remove the camshaft large inner gear.
PULLING LARGE GEAR (Typical Example)4. To install, heat both gears to a maximum temperature of 600° F. (315° C).5. Align keyway of large gear with key in camshaft. Install large inner gear on camshaft with timing mark on gear aligned with timing mark on crankshaft gear.6. Install the spacer and small outer gear.
Do not drive gears onto camshaft. Serious damage can result to camshaft or camshaft thrust pin.
Engines With Engine Camshaft Mounted Timing Advance
1. Remove screw (1) and washer (2) from end of camshaft.
REMOVING TIMING ADVANCE RETAINING SCREW
1. Screw. 2. Washer.2. Remove timing advance unit from the camshaft.3. Install puller (A), with spacer (C) over the shaft in the camshaft and spacer (B) on spacer (C) as shown and remove the gear from the camshaft.
REMOVING GEAR (Typical Example)
A. 1P2321 Puller. B. 8S5579 Spacer. C. 9S9155 Spacer.To install the gear use the following procedure:1.