101492-0980 ZEXEL 9 400 612 995 BOSCH INJECTION-PUMP ASSEMBLY 9400612995 1014920980 8972118880

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 612 995 9400612995

ZEXEL 101492-0980 1014920980

ISUZU 8972118880 8972118880

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Buy INJECTION-PUMP ASSEMBLY 101492-0980 zexel genuine, new aftermarket engine parts with delivery

Service parts 101492-0980 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-9981

3. GOVERNOR 105400-8800

4. SUPPLY PUMP 105220-7280

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156639-1720

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-6211

11. Nozzle and Holder 8-97134-524-0

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

13. NOZZLE-HOLDER 105048-3230

14. NOZZLE

105017-2030

15. NOZZLE SET

Include in #1:

101492-0980 as INJECTION-PUMP ASSEMBLY

106692-4122 as _

Cross reference number

BOSCH 9 400 612 995 9400612995

ZEXEL 101492-0980 1014920980

ISUZU 8972118880 8972118880

Zexel num

Bosch num

Firm num

Name

101492-0980

9 400 612 995

8972118880 ISUZU

INJECTION-PUMP ASSEMBLY
4JB1 K 14BC INJECTION PUMP ASSY 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

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

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

Rack position
Point A R=A

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 8.3

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 59 58 60

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 6.6+-0.5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 11.5 9.5 13.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

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

Injection quantity adjustment_03

Adjusting point D

Rack position 14++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 70 70 102

Fixing the lever *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Set idle sub-spring (4)Main spring setting
----------
K=7
----------

Speed control lever angle

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

----------
a=4deg+-5deg b=16deg+-5deg c=35deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal
----------

----------
a=0deg+-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=14deg
----------
a=(210deg)

Information:

1. Remove the bolts (2) that hold suction bell and tubes (1) to the engine block. 2. Remove O-ring seals (3) from the tubes. Inspect O-ring seals for damage. Make a replacement if necessary. 3. Remove clip (5) and then remove screen (4). Clean the screen if necessary. 4. Remove the bolts (7) that hold the oil pump to the engine block. Remove oil pump (6).Install Oil Pump
1. Put the oil pump (1) in position on the engine block and install the bolts that hold it. 2. Install screen (2) with the clip (3) that holds it. 3. Put a small amount of clean oil on O-ring seals (4). Install the O-ring seals on the tubes. 4. Put tubes (5) in position in the oil pump.5. Put suction bell (6) and support in position on the engine block and install the four bolts that hold it.End By:a. install oil panDisassemble Oil Pump
Start By:a. remove oil pump 1. Remove bolts (1) and cover (2). Remove spacer from cover, then remove spring and plunger from pump bore. 2. Remove bolt (4), washer (3) and gear (5) from the pump. 3. Remove bolts (7) then remove shaft assembly (6) from the pump. 4. Remove bolts (8) then remove cover assembly (9) from the pump body. 5. Use Tooling (A) to remove bearings (10) from cover assembly (9). 6. Remove shaft and gear assembly (11) from the pump body. 7. Remove bolt and washer from gear (12). Use Tool (B) to remove gear (12) 8. Remove shaft and gear assembly (13) from the pump body. 9. Use Tooling (A) to remove bearings from pump body bore.Assemble Oil Pump
1. Use Tooling (A) to install bearings (2) until they are even with the outside surface of main pump body (1). Install bearings (2) so the junctions in the bearings are 30 15 degrees from the center line of the bearing bores and toward the oil pump outlet passage as shown. 2. Install shaft and gear assembly (3) in the pump body. Install key in shaft. 3. Install gear (4) on the shaft. Install bolt and washer on the shaft. 4. Install shaft and gear assembly (5) in the pump body. 5. Install bearings (7) in the cover assembly (6) with Tooling (A). Install the bearings until they are in position the same distance in from each side of the cover assembly. Install the bearings with the oil holes in the bearings in alignment with the oil holes in the cover assembly and the junctions in the bearings in alignment with the cavity in the cover assembly. 6. Install cover assembly (6) on the pump body. 7. Install shaft assembly (8) on the oil pump body with the two bolts that hold it. 8. Install gear (9) on shaft assembly. Install washer and bolt on gear (9). 9. Install plunger (10), spring (13) and spacer (11) in the pump body. Install cover (12) and the bolts (14) that hold it.End By:a. install oil pump