Information injection-pump assembly
ZEXEL
101431-0680
1014310680
ISUZU
5156010373
5156010373
Rating:
Service parts 101431-0680 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
5-15300-039-1
12.
Open Pre:MPa(Kqf/cm2)
11.8{120}
15.
NOZZLE SET
Cross reference number
ZEXEL
101431-0680
1014310680
ISUZU
5156010373
5156010373
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 6-2-600
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-3-4-2
Pre-stroke
mm
2.25
2.2
2.3
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
12.4
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
40.4
39.3
41.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
12
Pump speed
r/min
1200
1200
1200
Average injection quantity
mm3/st.
41.3
39.8
42.8
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
7.5+-0.5
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
9
7.7
10.3
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Injection quantity adjustment_04
Adjusting point
D
Rack position
17.5+-0.
5
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
58
58
Fixing the lever
*
Timer adjustment
Pump speed
r/min
500+-50
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
800
Advance angle
deg.
1
0.5
1.5
Timer adjustment_03
Pump speed
r/min
1050
Advance angle
deg.
2
1.2
2.7
Timer adjustment_04
Pump speed
r/min
1500
Advance angle
deg.
4.5
3.9
4.9
Timer adjustment_05
Pump speed
r/min
1750
Advance angle
deg.
6
5.5
6.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)At rack cap installation: R1
----------
K=10 R1=(17.5)mm
----------
----------
K=10 R1=(17.5)mm
----------
Speed control lever angle
F:Full speed
(1)Beginning of speed increase
(2)Fix idle side stopper bolt.
----------
----------
a=23deg+-5deg b=31deg+-5deg
----------
----------
a=23deg+-5deg b=31deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Gear mark Z for the No. 4 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=14deg
----------
a=(60deg)
----------
aa=14deg
----------
a=(60deg)
Information:
3. Loosen the clamps on breather tube (1) and pull it back for clearance. 4. Remove bolt (2) from the cover on the side of the cylinder block. 5. Remove the three bolts that hold cover (3) to the water pump. Remove cover (3) from the water pump. 6. Remove the two bolts, and remove elbow (4) from bonnet (5). Remove the two bolts, and remove bonnet (5) from the water pump. It is not necessary to remove bolts (6). These bolts only hold the cover to the timing gear cover.7. Remove six long bolts (7) that hold the water pump to the timing gear cover. Remove water pump (8).Install Water Pump
1. Check the O-ring seals and gaskets, and make replacements if needed. 2. Make sure O-ring seal (9) is in position on the water pump. Put water pump (8) into position in the timing gear cover. Install the bolts that hold the water pump in place. 3. Make sure the gaskets are in place. Connect bonnet (5) to the water pump. Connect elbow (4) to the bonnet. 4. Make sure O-ring seal (10) is in position, and install cover (3) on the water pump. 5. Install bolt (2) on the cover on the side of the engine. 6. Put breather tube (1) in position, and install the clamps that hold it.7. Install the alternator mounting group and alternator on the engine.8. Install the water temperature regulator and manifold. See the topic Install Water Temperature Regulator and Manifold.9. Fill cooling system to the correct level. See the Maintenance Guide.Disassemble And Assemble Water Pump
Start By: The water pump seal can be replaced without removing the water pump from the engine.An intermittent leakage of a small amount of coolant from the hole in the water pump housing is not and indication of a water pump seal failure. This is required to provide lubrication for the seal. Replace the water pump seal only if a large amount of leakage or a constant flow of coolant is observed draining from the water pump housing. 1. Remove O-ring seal (3) from adapter (4). Remove the adapter from housing (7). Remove the O-ring seal from the outside of the adapter.2. Remove bolt (1) an washer (2). Use tooling (A) to remove impeller (6) from shaft (13).3. Remove spring and seal (5) from the shaft.4. Remove four bolts (16) from retainer (12) that hold the shaft assembly to the pump housing. Remove O-ring seal (18) from housing (7).5. Remove gear and shaft assembly (17) from the housing. Remove bolt (15), retainer (14), and retainer (12) from the shaft assembly.6. Use a press to remove shaft (13) from the gear. Remove bearing (9), spacer (10), and bearing (11) from the shaft.7. Remove lip-type seal (8) from the housing.8. Turn the housing over, and remove ceramic ring (20) and seal (19) from the housing. The following steps are for the assembly of the water pump.9. Use 6V1541 Quick Cure Primer and clean shaft (13) and the seal
1. Check the O-ring seals and gaskets, and make replacements if needed. 2. Make sure O-ring seal (9) is in position on the water pump. Put water pump (8) into position in the timing gear cover. Install the bolts that hold the water pump in place. 3. Make sure the gaskets are in place. Connect bonnet (5) to the water pump. Connect elbow (4) to the bonnet. 4. Make sure O-ring seal (10) is in position, and install cover (3) on the water pump. 5. Install bolt (2) on the cover on the side of the engine. 6. Put breather tube (1) in position, and install the clamps that hold it.7. Install the alternator mounting group and alternator on the engine.8. Install the water temperature regulator and manifold. See the topic Install Water Temperature Regulator and Manifold.9. Fill cooling system to the correct level. See the Maintenance Guide.Disassemble And Assemble Water Pump
Start By: The water pump seal can be replaced without removing the water pump from the engine.An intermittent leakage of a small amount of coolant from the hole in the water pump housing is not and indication of a water pump seal failure. This is required to provide lubrication for the seal. Replace the water pump seal only if a large amount of leakage or a constant flow of coolant is observed draining from the water pump housing. 1. Remove O-ring seal (3) from adapter (4). Remove the adapter from housing (7). Remove the O-ring seal from the outside of the adapter.2. Remove bolt (1) an washer (2). Use tooling (A) to remove impeller (6) from shaft (13).3. Remove spring and seal (5) from the shaft.4. Remove four bolts (16) from retainer (12) that hold the shaft assembly to the pump housing. Remove O-ring seal (18) from housing (7).5. Remove gear and shaft assembly (17) from the housing. Remove bolt (15), retainer (14), and retainer (12) from the shaft assembly.6. Use a press to remove shaft (13) from the gear. Remove bearing (9), spacer (10), and bearing (11) from the shaft.7. Remove lip-type seal (8) from the housing.8. Turn the housing over, and remove ceramic ring (20) and seal (19) from the housing. The following steps are for the assembly of the water pump.9. Use 6V1541 Quick Cure Primer and clean shaft (13) and the seal