101492-0660 ZEXEL 9 400 614 405 BOSCH INJECTION-PUMP ASSEMBLY 9400614405 1014920660 8970480040

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 614 405 9400614405

ZEXEL 101492-0660 1014920660

ISUZU 8970480040 8970480040

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Buy INJECTION-PUMP ASSEMBLY 101492-0660 zexel genuine, new aftermarket engine parts with delivery

Service parts 101492-0660 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-9880

3. GOVERNOR 105400-7810

4. SUPPLY PUMP 105220-5850

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156637-0620

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4223

11. Nozzle and Holder 8-94407-879-3

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

13. NOZZLE-HOLDER 105048-3230

14. NOZZLE

105017-1550

15. NOZZLE SET

Include in #1:

101492-0660 as INJECTION-PUMP ASSEMBLY

106682-9242 as _

Cross reference number

BOSCH 9 400 614 405 9400614405

ZEXEL 101492-0660 1014920660

ISUZU 8970480040 8970480040

Zexel num

Bosch num

Firm num

Name

101492-0660

9 400 614 405

8970480040 ISUZU

INJECTION-PUMP ASSEMBLY
4JB1 * K 14BC PE4A,5A, PE

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
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

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 11.2

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 69.2 68.2 70.2

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 7.8+-0.5

Pump speed r/min 450 450 450

Average injection quantity mm3/st. 9.6 7.6 11.6

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)Set idle sub-spring (3)Main spring setting
----------
K=11
----------

Speed control lever angle

F:Full speed I:Idle S:Stop
----------

----------
a=11deg+-5deg b=23deg+-5deg c=35deg+-3deg

Stop lever angle

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

----------
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=17deg
----------
a=(200deg)

Information:

Start By:a. remove fuel injection linesb. remove fuel filter and basec. remove fuel transfer pump The following illustrations are of a 3304 Engine. 1. Disconnect the governor control linkage from the governor.2. On 3304 Engines only: remove oil supply line (1), oil drain line (2) and heat shield (3). Remove the O-ring seal from oil drain line (2) if it is damaged. Remove the gaskets and screen from the top of the turbocharger.3. Disconnect fuel drain lines (4) and (5) from the fuel injection pump housing and governor. 4. Remove the nuts, washers and cover from the timing gear housing. Remove studs (6) if they are damaged or loose.5. Loosen bolt (7) enough to leave a gap of 3.18 mm (.125 in) between washer (8) and the fuel pump drive gear.6. Install Tool (A) as shown. Tighten the stud to pull the fuel pump drive gear loose from the taper on the fuel injection pump camshaft.7. Remove Tool (A), bolt (7) and washer (8) from the engine. 8. Fasten a nylon strap and hoist to the fuel injection pump housing and governor. The 3304 fuel injection pump housing and governor weighs 24 kg (53 lb). The 3306 fuel injection pump housing and governor weighs 29 kg (64 lb).9. Remove bolt (9), bolt (10), three nuts (11) and the fuel injection pump housing and governor. Remove the two O-ring seals from the bottom and the two O-ring seals from the front of the fuel injection pump housing and governor.Install Fuel Injection Pump Housing & Governor
The following illustrations are of a 3304 Engine. 1. Put clean engine oil on the O-ring seals. Install O-ring seals (1) in the bottom and O-ring seals (2) in the front of the fuel injection pump housing and governor. 2. Make sure O-ring seals (1) and (2) stay in position in the fuel injection pump housing and governor. Fasten a hoist to the fuel injection pump housing and governor, and put it in position on the engine. Install the two bolts at location (5) and the three nuts on studs (3) to hold the fuel injection pump housing and governor in position.3. Remove the bolts that hold cover (4) in position. Remove cover (4) and the gasket. 4. Put Tool (A) in position as shown. Install the bolt that holds the fuel pump drive gear to the fuel injection pump camshaft without the washer. This will allow the camshaft in the fuel system to be turned.5. Put pressure on the end of Tool (A) and turn the camshaft slowly until the Tool drops into the groove (slot) in the camshaft. Leave Tool (A) in position in the groove (slot). Remove the bolt from the end of the camshaft. 6. Install washer (6) with the large diameter toward the front of the engine. Install bolt (7) and tighten it to a torque of 6.8 N m (60 lb in).7. Install Tool (B) as shown in the flywheel housing. Make sure bolt (7) does not loosen as