Information injection-pump assembly
BOSCH
9 400 614 376
9400614376
ZEXEL
101492-0321
1014920321
ISUZU
8944741531
8944741531
Rating:
Service parts 101492-0321 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-94451-183-3
12.
Open Pre:MPa(Kqf/cm2)
19.6(200)
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 614 376
9400614376
ZEXEL
101492-0321
1014920321
ISUZU
8944741531
8944741531
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
Overflow valve
131424-0820
Overflow valve opening pressure
kPa
127
107
147
Overflow valve opening pressure
kgf/cm2
1.3
1.1
1.5
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
3.3
3.25
3.35
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
9
Pump speed
r/min
1600
1600
1600
Average injection quantity
mm3/st.
54
53
55
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
7.6+-0.5
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
8
6
10
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Delivered with idle spring not operating.
(3)Deliver without the torque control spring operating.
----------
K=18
----------
----------
K=18
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=129deg+-5deg b=31deg+-5deg
----------
----------
a=129deg+-5deg b=31deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=2.5deg+-5deg b=53deg+-5deg
----------
----------
a=2.5deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'V' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=18deg
----------
a=(200deg)
----------
aa=18deg
----------
a=(200deg)
Information:
(1) 4.236 Rocker Lever: Inside diameter of rocker arm ... 19.063 to 19.101 mm (.7505 to .7520 in)Rocker arm clearance on rocker shaft ... 0.03 to 0.089 mm (.001 to .0035 in)Maximum permissible clearance (worn) ... 0.13 mm (.005 in)T4.236 Rocker Lever: Inside diameter of rocker arm ... 22.225 to 22.255 mm (.8750 to .8762 in)Outside diameter of bushing ... 22.276 to 22.314 mm (.8770 to .8785 in)Interference fit of bushing in rocker arm ... 0.020 to 0.089 mm (.0008 to .0035 in)Diameter of bushing ... 19.063 to 19.101 mm (.7505 to .7520 in)Rocker arm clearance between shaft and bushing (new) ... 0.03 to 0.089 mm (.001 to .0035 in)Maximum permissible clearance (worn) ... 0.13 mm (.005 in)(2) Diameter of rocker shaft ... 19.012 to 19.037 mm (.7485 to .7495 in)(3) Install seal (3) in cylinder head before rocker shaft is installed.(4) Length of push rods ... 270.46 to 271.98 mm (10.648 to 10.708 in) Diameter of push rods ... 7.87 to 7.92 mm (.310 to .312 in)(5) End play of camshaft (new) ... 0.10 to 0.41 mm (.004 to .016 in) Maximum permissible end play (worn) ... 0.51 mm (.020 in)(6) Torque for bolt that holds camshaft gear on camshaft ... 70 N m (50 lb ft)(7) Camshaft thrust washer: A new cylinder block, camshaft and thrust washer have been introduced on the 4.236 and T4.236 engines. The thrust washer recess in the new block is deeper. The thrust washer thickness remains the same. The change became effective at engine serial number LD or LJ-----U106654N and up. The engine serial number is located above the fuel injection pump on the block.Thickness of camshaft thrust washer ... 5.49 to 5.54 mm (.216 to .218 in)Outside diameter of thrust washer ... 72.95 to 73.00 mm (2.872 to 2.874 in)Cylinder block recess diameter for thrust washer ... 73.03 to 73.28 mm (2.875 to 2.885 in)Clearance of thrust washer in recess ... 0.03 to 0.33 mm (.001 to .013 in)Inside diameter of thrust washer ... 44.45 mm (1.750 in)Thickness of thrust washer ... 5.49 to 5.54 mm (.216 to .218 in) The recess in the cylinder block is deeper for current models.Earlier Models:Cylinder block recess depth for thrust washer ... 4.75 to 4.83 mm (.187 to .190 in)Projection of thrust washer above cylinder block front face ... 0.66 to 0.79 mm (.026 to .031 in)Current Models:Cylinder block recess depth for thrust washer ... 5.38 to 5.49 mm (.212 to .216 in)Projection of thrust washer above cylinder block face ... 0.0 to 0.13 mm (.000 to .005 in)(8) Diameter of camshaft journals: No. 1 journal ... 50.71 to 50.737 mm (1.9965 to 1.9975 in)Minimum permissible diameter ... 50.660 mm (1.9945 in)No. 2 journal ... 50.457 to 50.483 mm (1.9865 to 1.9875 in)Minimum permissible diameter ... 50.406 mm (1.9845 in)No. 3 journal ... 49.949 to 49.975 mm (1.9665 to 1.9675 in)Minimum permissible diameter ... 49.898 mm (1.9645 in)See Cylinder Block for camshaft bore specifications.(9)