101402-9431 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014029431

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101402-9431 1014029431

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Service parts 101402-9431 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8451

3. GOVERNOR 105419-2340

4. SUPPLY PUMP 105220-7170

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2)

13. NOZZLE-HOLDER

14. NOZZLE

15. NOZZLE SET

Include in #1:

101402-9201 as _

101402-9431 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101402-9431 1014029431

Zexel num

Bosch num

Firm num

Name

101402-9431

INJECTION-PUMP ASSEMBLY

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 131424-1520

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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 3.6 3.55 3.65

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 11.4

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 76.5 75.5 77.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 7.2+-0.5

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 11.5 10.5 12.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 85 80 90

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)Main spring setting (5)Set idle sub-spring
----------
K=9
----------

Speed control lever angle

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

----------
a=2deg+-5deg b=12deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=7deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of camshaft's key groove at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(60deg)

Information:

Start By:a. remove cylinder headb. remove oil panc. remove oil pumpd. remove cooling tubes 1. Check the connecting rods and caps for their identification and location.2. Remove rod cap nuts (1) and cap (2) from connecting rod (3). Remove the lower half of bearing (4) from cap (2).
To protect the crankshaft from the threaded portion of connecting rod bolts (5), cut a short piece of rubber hose and install it over both rod bolts (5).
3. Remove the piston and connecting rod, then remove the upper half of rod bearing (4). The following steps are for the installation of the pistons and connecting rod assemblies.4. Put clean oil on piston rings, connecting rod bearings and cylinder bore.5. Position the piston ring end gaps 120° apart and install tooling (A).6. Put the short pieces of hose over the threaded portion of rod bolts (5), to protect crankshaft.7. With number one crankshaft throw at bottom center, install the piston and connecting rod. Engines which use one piece pistons have the word "FRONT" stamped on the crown of the piston. Make sure the word "FRONT" is toward the front of the engine when the piston is installed.8. Taking care to line up connecting rod and crankshaft, carefully tap piston into cylinder bore until tooling (A) comes off the piston. 9. Before connecting rod (3) comes in contact with the crankshaft, install upper half of rod bearing (4). Be sure the bearing tab engages the groove in the connecting rod.10. Put engine oil on upper rod bearing surface, then tap piston down, guiding connecting rod onto crankshaft.11. Position lower half of rod bearing (4) in corresponding numbered rod cap (2). Be sure the bearing tab engages the grove in the rod caps.12. Put engine oil on the lower rod bearing surface, then install the rod cap. Install the bearing cap on the connecting rod with the number on the bearing (rod) cap on the same side and same number as on the connecting rod.13. Put engine oil on the threads of bolts (5). Install rod cap nuts (1) and tighten them to a torque of 54 7 N m (40 5 lb.ft.).14. Put an alignment mark on cap and nut. Then, tighten each nut an additional 60° 5° (1/6 turn).15. Repeat the steps for the remainder of the pistons and connecting rods.End By:a. install cooling tubesb. install oil pumpc. install oil pand. install cylinder headDisassemble And Assemble Pistons And Connecting Rods
Start By:a. remove pistons and connecting rods 1. Remove snap ring (1) remove piston pin (2). Separate piston (3) and connecting rod (4).
One Piece Piston
Two Piece Piston2. Use tooling (A) and remove piston rings (5). The following steps are for the assembly of the pistons and connecting rods.3. Check the clearance between the ends of the piston rings (5). See the topic, Pistons And Rings in the Specifications section of the service manual. The oil ring is to be installed over the spring with the end gap 180° from the