101402-8100 ZEXEL 9 400 612 742 BOSCH INJECTION-PUMP ASSEMBLY 9400612742 1014028100 8973272420

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 612 742 9400612742

ZEXEL 101402-8100 1014028100

ISUZU 8973272420 8973272420

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Buy INJECTION-PUMP ASSEMBLY 101402-8100 zexel genuine, new aftermarket engine parts with delivery

Service parts 101402-8100 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-9700

3. GOVERNOR 105400-9490

4. SUPPLY PUMP 105220-6710

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156643-5220

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-8291

11. Nozzle and Holder 8-97327-244-0

12. Open Pre:MPa(Kqf/cm2) 19.1{195}/25.0{255}

13. NOZZLE-HOLDER 105048-2300

14. NOZZLE

15. NOZZLE SET 105019-1350

Include in #1:

101402-8100 as INJECTION-PUMP ASSEMBLY

106674-4066 as _

Cross reference number

BOSCH 9 400 612 742 9400612742

ZEXEL 101402-8100 1014028100

ISUZU 8973272420 8973272420

Zexel num

Bosch num

Firm num

Name

101402-8100

9 400 612 742

8973272420 ISUZU

INJECTION-PUMP ASSEMBLY
4JG1 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 131424-0820

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-3-4-2

Pre-stroke mm 2.6 2.55 2.65

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 9.3

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 65 64 66

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 6+-0.5

Pump speed r/min 585 585 585

Average injection quantity mm3/st. 12 10 14

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 (5)Rack difference between N = N1 and N = N2
----------
K=9 N1=1100r/min N2=900r/min
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Speed control lever angle

F:Full speed I:Idle S:Stop
----------

----------
a=2deg+-5deg b=19deg+-5deg c=31deg+-3deg

Stop lever angle

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

----------
a=0deg+-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=11deg
----------
a=(210deg)

Information:

(1) Thickness of spacer plate ... 8.585 0.025 mm (.3379 .0009 in)Thickness of gasket that is placed between spacer plate and cylinder block ... 0.208 0.025 mm (.0081 .0009 in)Height of liner over spacer plate, under installation pressure ... 0.13 0.08 mm (.005 .003 in)(2) Height of four dowels above top surface of cylinder block:End dowels (Put 7M7456 Bearing Mount Compound on two end dowels at installation) ... 18.5 0.5 mm (.73 .02 in)Middle dowels ... 16.0 0.5 mm (.63 .02 in)(3) Dimension (new) from centerline of crankshaft bearing bore to top of block (top deck) ... 425.45 0.15 mm (16.750 .006 in)Minimum dimension from centerline of crankshaft bearing bore to top of block (top deck) ... 425.02 mm (16.733 in) The flatness across the whole contact surface of the block must be within 0.10 mm (.004 in) and within 0.05 mm (.002 in) for any 177 mm (7.0 in) section of the surface. The surface finish specification is 3.2 micrometers (125 micro-inches) maximum.(4) Bore in block for camshaft bearings ... 76.835 0.018 mm (3.0250 .0007 in) Install bearings with the oil holes in the bearings on the horizontal centerline. Make sure the bearing joint position is above the oil holes.(5) Bore in the block for the main bearings:Standard, original size (new) ... 129.891 0.013 mm (5.1138 .0005 in)0.64 mm (.025 in) larger than original size ... 130.526 0.013 mm (5.1388 .0005 in)(6) Distance from front of rear face of cylinder block to end of dowels ... 19.1 0.05 mm (.75 .02 in)(7) Width of main bearing cap ... 215.900 0.013 mm (8.5000 .0005 in)Width of block for main bearing cap ... 215.900 0.013 mm (8.5000 .0005 in)Clearance between main bearing cap and cylinder block ... 0.025 mm (.0009 in) tight to 0.025 mm (.0009 in) loose
Tightening Procedure For Main Bearings(8) Torque for the bolts that hold the caps for the main bearings: Install the main bearing caps with the marks (arrow) toward the front of the engine. Install each cap in the correct position by putting the number stamped on the bottom of the cap toward the corresponding number cast on left side of the cylinder block at the pan rail.a. Put 2P2506 Thread Lubricant on the threads of the bolts.b. Tighten the bolts first on the bearing tab side of the cap to ... 260 14 N m (190 10 lb ft)c. Tighten the bolts on the opposite side to ... 260 14 N m (190 10 lb ft)d. Put a mark on each bolt and cap.e. Tighten the bolts on the opposite side, from the mark ... 120 5°f. Tighten the bolts on the bearing tab side of the cap, from the mark ... 120 5°(9) Dimension (new) from centerline of crankshaft bearing bore to bottom of block (pan rails) ... 165.10 0.10 mm