101402-8030 ZEXEL 9 400 612 605 BOSCH INJECTION-PUMP ASSEMBLY 9400612605 1014028030 8973195040

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 612 605 9400612605

ZEXEL 101402-8030 1014028030

ISUZU 8973195040 8973195040

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Buy INJECTION-PUMP ASSEMBLY 101402-8030 zexel genuine, new aftermarket engine parts with delivery

Service parts 101402-8030 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8390

3. GOVERNOR 105411-2410

4. SUPPLY PUMP 105220-7140

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156639-9620

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-5250

11. Nozzle and Holder 8-97288-122-0

12. Open Pre:MPa(Kqf/cm2) 22.1{225}

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE 105025-3540

15. NOZZLE SET

Include in #1:

101402-8030 as INJECTION-PUMP ASSEMBLY

106671-4684 as _

Cross reference number

BOSCH 9 400 612 605 9400612605

ZEXEL 101402-8030 1014028030

ISUZU 8973195040 8973195040

Zexel num

Bosch num

Firm num

Name

101402-8030

9 400 612 605

8973195040 ISUZU

INJECTION-PUMP ASSEMBLY
4BG1-T K 14BD INJECTION PUMP ASSY PE4AD 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 3.45 3.4 3.5

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 10

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 106 104.4 107.6

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 173 173

Boost pressure mmHg 1300 1300

Injection quantity adjustment_02

Adjusting point B

Rack position 7.3+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 14 12.7 15.3

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position 7.65

Boost pressure kPa 20 16 24

Boost pressure mmHg 150 120 180

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position 9.15

Boost pressure kPa 160 153.3 166.7

Boost pressure mmHg 1200 1150 1250

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)Boost compensator stroke (4)Set idle sub-spring (5)Main spring setting
----------
K=17
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa
----------
aa=70mm
----------
a=22deg+-5deg b=32deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa, speed = bb (stamp at delivery) (2)Normal (3)Use the hole above R = cc
----------
aa=1-0.5mm bb=0r/min cc=40mm
----------
a=32deg+-5deg b=(55deg)

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=17deg
----------
a=(90deg)

Information:

start by:a) remove flywheel housingb) remove valve liftersc) remove pistonsd) remove timing gear cover and oil pump1. Fasten a hoist and put the engine in position on tool (A).2. Turn the crankshaft until the timing mark on the crankshaft gear is in alignment with the timing mark on the camshaft gear. For more detail about removal of main bearings see REMOVE AND INSTALL CRANKSHAFT MAIN BEARINGS. 3. Remove bolts (1) and main bearing caps (2). Remove the lower halves of the main bearings from the caps.4. Install two of the bolts that hold the flywheel in place in the end of crankshaft. 5. Fasten a hoist and remove crankshaft (3) from the engine. The weight of the crankshaft is 54 kg (120 lb.).
Be careful not to cause damage to the crankshaft journals when the crankshaft is removed.
6. Remove the upper halves of the main bearings from the cylinder block.7. Install tooling (B) and remove the gear from the crankshaft. Install Crankshaft And Gear
1. Install the key for the crankshaft gear so it is even with the end of the crankshaft.2. Heat the crankshaft gear to a maximum temperature of 260°C (500°F). Install the gear on the crankshaft with the timing mark on the gear toward the pulley end of the crankshaft.3. Install the thrust bearing for the No. 4 main. Install the bearings dry when the clearance checks are made. Put clean engine oil on the bearings for final assembly.4. Install the upper main bearings (the bearings with oil hole) into the engine block.5. Install two of the bolts that hold the flywheel in place in the end of the crankshaft. Fasten a hoist and put the crankshaft in position in the block. Make sure the timing mark on the crankshaft gear is in alignment with the timing mark on the camshaft gear. For more detail about installation of main bearings see REMOVE AND INSTALL CRANKSHAFT MAIN BEARINGS.
When the bearing caps are installed, make sure the number on the side of the cap is next to and respective with the number on the engine block.
When the bearing clearance is checked and the engine is in a vertical position, the crankshaft will have to be lifted up with a force equal to the weight of the crankshaft and held against the upper halves of the main bearings to get a correct measurement with Plastigage. The Plastigage will not hold the weight of the crankshaft and give a correct indication. If the engine is in a horizontal position, such as on an engine stand, it is not necessary to hold the crankshaft up. Do not turn crankshaft when Plastigage is in position to check clearance. 6. Check the bearing clearance with Plastigage. Put the lower main bearings into the caps. Put the caps in position and install the bolts. Tighten the bolts in number sequence as follows: a) Tighten bolts 1 through 10 to a torque of 40 4 N m (30 3 lb.ft.).
Do not use an impact