101402-7970 ZEXEL 9 400 612 452 BOSCH INJECTION-PUMP ASSEMBLY 9400612452 1014027970 8973137010

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 612 452 9400612452

ZEXEL 101402-7970 1014027970

ISUZU 8973137010 8973137010

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Buy INJECTION-PUMP ASSEMBLY 101402-7970 zexel genuine, new aftermarket engine parts with delivery

Service parts 101402-7970 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8900

3. GOVERNOR 105419-4830

4. SUPPLY PUMP 105220-6250

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156643-2520

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-5130

11. Nozzle and Holder 8-97222-170-0

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

13. NOZZLE-HOLDER 105030-4750

14. NOZZLE

105025-3040

15. NOZZLE SET

Include in #1:

101402-7970 as INJECTION-PUMP ASSEMBLY

106671-4304 as _

Cross reference number

BOSCH 9 400 612 452 9400612452

ZEXEL 101402-7970 1014027970

ISUZU 8973137010 8973137010

Zexel num

Bosch num

Firm num

Name

101402-7970

9 400 612 452

8973137010 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 127 107 147

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 3.4 3.35 3.45

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 8.6

Pump speed r/min 1025 1025 1025

Average injection quantity mm3/st. 86.5 85.4 87.6

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 6.3+-0.5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 12 10.6 13.4

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point D

Rack position 8.8++

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 (5)Main spring setting
----------
K=14
----------

Speed control lever angle

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

----------
a=(3deg)+-5deg b=35deg+-5deg c=(20deg)+-5deg

Stop lever angle

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

----------
a=13deg+-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=9deg
----------
a=(100deg)

Information:

start by:a) remove exhaust manifoldb) remove air inlet manifoldc) remove valve coversd) remove fuel injection linese) remove fuel injection nozzles1. Remove the coolant from the cooling system. 2. Remove clamp (2) from water sleeves (1) in each cylinder head. Push the water sleeves into the timing gear cover with tool (A) and a screwdriver. 3. Remove bolt (3) from the bracket on the dipstick tube. 4. Remove bolts (4) and stud (5) from the heads.
Make sure the fuel injection nozzles are removed before the cylinder heads are removed. The fuel injection nozzles go through the cylinder heads and the nozzle tips can be broken off if the nozzles are not removed from the heads.
5. Install tooling (B) and fasten a hoist. Remove bolts (7), cylinder head (6) and the gasket. The weight of the cylinder head is 54 kg (120 lb.).Install Cylinder Heads
1. Clean the contact surfaces of the cylinder head and cylinder block. Make sure the surfaces are clean and dry. Install a new cylinder head gasket. Clean the bore in the cylinder head for the water sleeves. Put oil on the seals on the water sleeves.2. Install tooling (B) in the cylinder head. Fasten a hoist and put the cylinder head in position on the cylinder block.3. Put 6V4876 Molykote Lubricant on the bolt threads and install the bolts that hold the cylinder head in their correct location. Tighten the bolts in the cylinder head according to the HEAD BOLT TORQUE CHART.
The higher cylinder head bolt torque may be used on earlier engines ONLY if the bolts are replaced with the later higher strength bolts (seven dash marks on the bolt head). If the earlier bolts are tightened to the later torque specification, they may yield (stretch) and lose their clamping force.
4. Install water sleeve into cylinder head with tool (A). Install the clamp on the water sleeves.5. Fill the cooling system with coolant to the correct level. end by:a) install fuel injection nozzlesb) install rocker shafts and push rodsc) install valve coversd) install air inlet manifolde) install exhaust manifold
Illustration 1. Bolt head identification.Disassemble Cylinder Heads
start by: a) remove cylinder heads1. Fasten a hoist and put the cylinder head in position on tool (A). Use adapter plates (1) from tooling (A) to hold the head in place. 2. Put the valve springs under compression with tool (C). 3. Remove the locks from the valves. Earlier engines have an inner valve spring. Later engines have only one valve spring and a spacer instead of inner spring.4. Remove tool (C), retainer, spring, washer and valve from the cylinder head. Put identification on the valve as to its location in the cylinder head. 5. Check the valve spring force with tool (B). For the correct spring force, see the subject VALVES in SPECIFICATIONS.6. Do Steps 2 through 5 for the remainder of the valves.7. Remove the valve seat inserts with tooling (D). The valve guides are part of the cylinder head. Measure the bore in each valve guide 19.0