101482-9080 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014829080

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101482-9080 1014829080

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Service parts 101482-9080 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101048-8130

3. GOVERNOR 105419-0440

4. SUPPLY PUMP 105220-5740

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4910

11. Nozzle and Holder 1660054T01

12. Open Pre:MPa(Kqf/cm2) 18.1(185)

13. NOZZLE-HOLDER 105048-3390

14. NOZZLE

105017-0900

15. NOZZLE SET

Include in #1:

101402-0510 as _

101482-9080 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101482-9080 1014829080

Zexel num

Bosch num

Firm num

Name

101482-9080

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 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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 3.2 3.15 3.25

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 10.7

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 59.9 58.9 60.9

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 9.2+-0.5

Pump speed r/min 450 450 450

Average injection quantity mm3/st. 8 6 10

Max. variation between cylinders % 0 -10 10

Fixing the rack *

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

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 62 62 72

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT (3)Set idle sub-spring (4)Main spring setting
----------
K=13
----------

Speed control lever angle

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

----------
a=10deg+-5deg b=19deg+-5deg

Stop lever angle

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

----------
a=12deg+-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:

1. Overview of Radiator-Equipped Engine's Cooling System
Flow of coolant2. Water Pump
2.1 Removal and Inspection
Removal sequence and points to check on water pump1 Cooling fan2 Water pump pulley3 Fan belt4 Water bypass hose5 Water pump assembly KEY POINTS FOR REMOVALRemoval of the water pump pulley and fan belt is possible after loosening slightly both the nut (1) on the alternator support bolt and the adjusting bolt (2). This allows the alternator to be moved and then the V-belt slackened.
Removing water pump pulley KEY POINTS FOR INSPECTIONTurn the pump by hand to check the impeller and shaft for smooth and quiet rotation. If irregular or noisy rotation is detected, replace them as an assembly.
Inspecting impeller and shaft rotation2.2 Installation
Correct locations of water pump mounting bolts KEY POINTS FOR INSPECTION(1) Install the six water pump mounting bolts in their correct locations by referring to the figure on the right for the nominal diameters and lengths from bottom of head.(2) Use a new gasket when installing the water pump.(3) Adjust the fan belt tension according to the following specification.
Fan belt tension adjustment
Unit: mm (in.)3. Thermostat
3.1 Disassembly
Removal sequence and points to check on thermostat1 Water outlet fitting2 Thermostat3 Thermostat fitting4 Water joint5 Temperature joint6 Thermounit3.2 Inspection KEY POINTS FOR INSPECTION(1) Operation Test of ThermostatPut the thermostat in a container of water. Heat the water and record both of the temperatures at which the valve starts to open and at which the valve lift reaches 8 mm (0.3 in.). If the readings do not conform to the specification below, replace the thermostat.
Carry out this operation with extreme care to avoid burns and prevent fire.
Operation test of thermostat(2) Thermounit InspectionPlace the temperature sensing section of the thermounit in a container of oil. Heat the oil to a temperature in each of the ranges shown below and measure the resistance between the terminal and body for each of the temperature. If the resistances are largely different from those specified below, replace the thermounit.
Unit: Ohms
Carry out this operation with extreme care to avoid burns and prevent fire.
Thermounit inspection3.3 InstallationExcept that the instructions shown below are to be followed, perform installation by following the removal sequence in reverse. KEY POINTS FOR INSTALLATION(1) Temperature jointApply sealant to the threads and tighten to the specified torque. (2) ThermostatMake sure that the thermostat flange is correctly fit into the counterbore in the intake manifold.
Installing temperature joint
Installing thermostat