Information injection-pump assembly
ZEXEL
101482-0390
1014820390
ISUZU
1156000471
1156000471
Rating:
Service parts 101482-0390 INJECTION-PUMP ASSEMBLY:
1.
_
2.
FUEL INJECTION PUMP
4.
SUPPLY PUMP
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
9-15300-184-2
12.
Open Pre:MPa(Kqf/cm2)
9.8{100}
15.
NOZZLE SET
Include in #1:
101482-0390
as INJECTION-PUMP ASSEMBLY
Include in #2:
104749-1180
as _
Cross reference number
ZEXEL
101482-0390
1014820390
ISUZU
1156000471
1156000471
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 holder
105031-2480
Opening pressure
MPa
9.8
Opening pressure
kgf/cm2
100
Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
132424-0620
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-3-4-2
Pre-stroke
mm
2.2
2.15
2.25
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
13.5
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
70
68.6
71.4
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
13.5
Pump speed
r/min
1300
1300
1300
Average injection quantity
mm3/st.
79
76.6
81.4
Max. variation between cylinders
%
0
-3
3
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
11.5
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
46.6
44.7
48.5
Max. variation between cylinders
%
0
-4
4
Fixing the rack
*
Injection quantity adjustment_04
Adjusting point
D
Rack position
10.3+-0.
5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
17.5
15.2
19.8
Max. variation between cylinders
%
0
-13
13
Fixing the rack
*
Test data Ex:
Governor adjustment
R:Rack position (mm)
P:Negative pressure
----------
----------
----------
----------
Speed control lever angle
(1)Rack position = aa
(2)Full position
----------
aa=17.5mm
----------
a=(8deg30min) b=14deg30min c=(11deg)
----------
aa=17.5mm
----------
a=(8deg30min) b=14deg30min c=(11deg)
Timing setting
(1)Pump vertical direction
(2)Position of pump side coupling's threaded hole at No. 1 cylinder's beginning of injection.
(3)-
(4)-
----------
----------
a=(10deg)
----------
----------
a=(10deg)
Information:
Installation procedure
Installation: Oil pan* Clean the sealant application surfaces of each part. * Apply a bead of sealant to each of the mating surfaces of the timing gear case, lower crankcase and front plate (at the two locations indicated the illustration). Installation: Oil pan* Clean the mating surfaces of each part. * Apply a bead of sealant to the mating surface of the oil pan evenly and without any breaks.* Mount the oil pan within three minutes of applying the sealant. Make sure that the sealant stays in place.
* Do not start the engine less than an hour after installation. If the oil pan mounting bolts were loosened or removed, be sure to reapply sealant.
Oil Pump
* Disassembly sequence1 Oil pump cover2 Driven gear3 Plug4 Relief valve spring5 Steel ball6 Gear and case7 O-ring*a Drive gear*b Oil pump gearP Locating pinX Non-reusable parts* Assembly sequenceFollow the disassembly procedure in reverse.Service standards (Unit: mm) Tightening torque (Unit: N m {kgf m}) Lubricant and/or sealant Inspection procedure
Inspection: Oil pump cover, driven gear, and gear and case* Measure the clearance between each gear's shaft and the oil pump cover, as well as between each gear's shaft and the gear and case. * If the measurements are not within the standard value range, replace the defective part(s). Inspection: Driven gear, drive gear and gear and case* Carry out the following inspection. Replace the oil pump if any defects are found. (1) Sinkage of each gear from gear and case end surface(2) Gear and case-to-tooth tip clearance for each gear Oil Cooler <Engine-Mounted Type, Engine Separately Mounted Type>, and Oil Filter <Engine-Mounted Type>
* Wipe up any spilled engine oil, as it can cause fires.* To avoid any risks of burns, take care not to touch the engine oil when the engine is hot.
* Make sure not to put any engine oil on the belt when working on the oil cooler and oil filter. Belt soiled with oil or grease may easily slip, resulting in deteriorated performance of the cooling system.* Do not reuse the oil filter elements by washing.
* Removal sequence1 Oil filter2 Plug3 Regulator valve spring4 Regulator valve5 Plug6 Bypass valve spring7 Bypass valve8 Oil cooler element9 Gasket10 Water drain plug11 Oil cooler body12 O-ring13 Gasket14 Water separate lipX Non-reusable parts* Installation sequenceFollow the removal sequence in reverse.Service standards (Unit: mm) Tightening torque (Unit: N m {kgf m}) Lubricant and/or sealant Special tools Removal procedure
Removal: Oil filter <Engine-mounted type> Inspection procedure
Inspection: Oil cooler element* Plug the outlet of the oil cooler element and connect a hose to the engine oil inlet port. Then, immerse the oil cooler element in a tank of water. * Apply an air pressure of 1.5 MPa {15 kgf/cm2} for 15 seconds through the hose, and check for any air leaks.* Replace the element if it leaks air.Installation procedure
Installation: Oil cooler <Engine-mounted type>* Clean the oil filter mounting surface of the oil cooler. * Apply a thin coat of engine oil on the oil filter gasket.* Screw in the
Installation: Oil pan* Clean the sealant application surfaces of each part. * Apply a bead of sealant to each of the mating surfaces of the timing gear case, lower crankcase and front plate (at the two locations indicated the illustration). Installation: Oil pan* Clean the mating surfaces of each part. * Apply a bead of sealant to the mating surface of the oil pan evenly and without any breaks.* Mount the oil pan within three minutes of applying the sealant. Make sure that the sealant stays in place.
* Do not start the engine less than an hour after installation. If the oil pan mounting bolts were loosened or removed, be sure to reapply sealant.
Oil Pump
* Disassembly sequence1 Oil pump cover2 Driven gear3 Plug4 Relief valve spring5 Steel ball6 Gear and case7 O-ring*a Drive gear*b Oil pump gearP Locating pinX Non-reusable parts* Assembly sequenceFollow the disassembly procedure in reverse.Service standards (Unit: mm) Tightening torque (Unit: N m {kgf m}) Lubricant and/or sealant Inspection procedure
Inspection: Oil pump cover, driven gear, and gear and case* Measure the clearance between each gear's shaft and the oil pump cover, as well as between each gear's shaft and the gear and case. * If the measurements are not within the standard value range, replace the defective part(s). Inspection: Driven gear, drive gear and gear and case* Carry out the following inspection. Replace the oil pump if any defects are found. (1) Sinkage of each gear from gear and case end surface(2) Gear and case-to-tooth tip clearance for each gear Oil Cooler <Engine-Mounted Type, Engine Separately Mounted Type>, and Oil Filter <Engine-Mounted Type>
* Wipe up any spilled engine oil, as it can cause fires.* To avoid any risks of burns, take care not to touch the engine oil when the engine is hot.
* Make sure not to put any engine oil on the belt when working on the oil cooler and oil filter. Belt soiled with oil or grease may easily slip, resulting in deteriorated performance of the cooling system.* Do not reuse the oil filter elements by washing.
* Removal sequence1 Oil filter2 Plug3 Regulator valve spring4 Regulator valve5 Plug6 Bypass valve spring7 Bypass valve8 Oil cooler element9 Gasket10 Water drain plug11 Oil cooler body12 O-ring13 Gasket14 Water separate lipX Non-reusable parts* Installation sequenceFollow the removal sequence in reverse.Service standards (Unit: mm) Tightening torque (Unit: N m {kgf m}) Lubricant and/or sealant Special tools Removal procedure
Removal: Oil filter <Engine-mounted type> Inspection procedure
Inspection: Oil cooler element* Plug the outlet of the oil cooler element and connect a hose to the engine oil inlet port. Then, immerse the oil cooler element in a tank of water. * Apply an air pressure of 1.5 MPa {15 kgf/cm2} for 15 seconds through the hose, and check for any air leaks.* Replace the element if it leaks air.Installation procedure
Installation: Oil cooler <Engine-mounted type>* Clean the oil filter mounting surface of the oil cooler. * Apply a thin coat of engine oil on the oil filter gasket.* Screw in the