101452-3092 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014523092

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101452-3092 1014523092

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Service parts 101452-3092 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101045-8090

3. GOVERNOR 105400-6990

4. SUPPLY PUMP 105220-5610

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105141-2520

11. Nozzle and Holder 6202-12-3100

12. Open Pre:MPa(Kqf/cm2) 11.8{120}

13. NOZZLE-HOLDER 105071-1450

14. NOZZLE 105000-1770

15. NOZZLE SET

Include in #1:

101452-3092 as INJECTION-PUMP ASSEMBLY

101601-4160 as _

Cross reference number

ZEXEL 101452-3092 1014523092

Zexel num

Bosch num

Firm num

Name

101452-3092

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

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 1-2-4-3

Pre-stroke mm 1.5 1.45 1.55

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cyl.1-2 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cal 1-3 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point A

Rack position 12

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 45.8 44.8 46.8

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 8.3+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 11 10 12

Max. variation between cylinders % 0 -15 15

Fixing the rack *

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

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK CAP: R1 (3)The torque control spring must does not have a set force. (4)Rack difference between N = N1 and N = N2 (5)Idle sub spring setting: L1.
----------
K=7 R1=(17.5)mm N1=900r/min N2=500r/min L1=6-0.5mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Set the pump speed at aa. ( At delivery ) (2)Set the pump speed at bb. (3)Stopper bolt setting
----------
aa=955r/min bb=750r/min
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a=(1deg)+-5deg b=(26deg)+-5deg c=(7deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)No return spring
----------

----------
a=43.5deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of key groove at No 1 cylinder's beginning of injection (3)Stamp aligning marks on the pump housing flange. (4)-
----------

----------
a=46deg18min+-3deg b=13deg42min+-30min

Information:

Install the pump cover onto the pump housing. Tighten the four middle bolts. Then, tighten the end bolts in a crisscross pattern. Tighten the bolts to a torque of 10.2 N m (90 lb in).Note: Make sure that the gasket is in place between the housing and the cover.
Repeat Step 1 and Step 2 in order to confirm the electrical connection for the pump coil was not damaged during the removal of the pump cover.
Install the oil inlet line adapter, inlet line, and harness connector to the pump.Note: After the HEUI pump is replaced or reassembled, the engine must be cranked for an extended length of time to fill the pump with oil.Note: Clear any diagnostic or event codes that activated during the initial start-up.
If the engine would not start before inspecting for debris and no debris was found in the HEUI pump, return to Step D in the diagnostic flow chart.If the engine would start before inspecting for debris and no debris was found in the HEUI pump, return to Step L in the diagnostic flow chart.If the pump is to be replaced, complete the checklist form in Special Instruction, REHS5031 that is provided with the service replacement part and insert the completed form back into the box containing the part that is being returned. Proceed to the section of this instruction titled "Oil Rail Cleaning Procedure" for the correct engine size that is being serviced.Oil Rail Cleaning Procedure For the C7 Engine
Illustration 12 g02702636
C7 Cylinder Head
Illustration 13 g02708256
The oil and fuel passages are the same for both the C7 and C9.
(6) Oil Rail for a HEUI fuel system
(7) Oil passage to injector bore
(8) Fuel passage
(9) Injector bore Note: Contain any oil and cleaner that will flow from the cylinder and the lines during the following process. Properly dispose of the oil and contaminated cleaner when work is complete.
Remove fuel injectors. Refer to Disassembly and Assembly for specific machine.
Install six plugs 9U-7080 Tapered Cap/Plug into the lower injector bores. The plugs will prevent oil, cleaners, and debris from entering the cylinders.
Remove the plugs from the front and rear of the cylinder head main oil gallery
Remove the pressure sensor from the cylinder head. Protect the sensor.
Clean out the two rail drain holes by removing their plugs and using the brake cleaner and long squirting straw to flush these passages to the oil rail.
Using the solvent gun with and without the