Information injection-pump assembly
ZEXEL
101492-1040
1014921040
Rating:
Service parts 101492-1040 INJECTION-PUMP ASSEMBLY:
1.
_
2.
FUEL INJECTION PUMP
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME019368
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}
15.
NOZZLE SET
Cross reference number
ZEXEL
101492-1040
1014921040
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
131424-4620
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
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
3.2
3.15
3.25
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
9.8
Pump speed
r/min
975
975
975
Average injection quantity
mm3/st.
66.4
65.4
67.4
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
8.2+-0.5
Pump speed
r/min
375
375
375
Average injection quantity
mm3/st.
7.5
6.2
8.8
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
C
Rack position
11.6+-0.
5
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
60.5
60.5
65.5
Fixing the lever
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK LIMIT
(3)Torque spring does not operate.
(4)Rack difference between N = N1 and N = N2
(5)Setting at shipping
(6)Idle sub spring setting: L1.
----------
K=7 N1=975r/min N2=600r/min L1=9.2+-0.1mm
----------
----------
K=7 N1=975r/min N2=600r/min L1=9.2+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)At shipping
(2)Stopper bolt setting
----------
----------
a=18deg+-5deg b=5deg+-5deg c=(12deg)
----------
----------
a=18deg+-5deg b=5deg+-5deg c=(12deg)
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=27deg+-5deg b=53deg+-5deg
----------
----------
a=27deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear mark '3' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=16deg
----------
a=(130deg)
----------
aa=16deg
----------
a=(130deg)
Information:
Start By:a. remove rocker shaft assembliesb. remove turbochargers1. Remove the valve cover bases from the cylinder head. 2. Remove sensor (7) from cylinder head (8). If necessary, remove the O-ring seal from sensor (7).3. Remove bolt and locknut (5).4. Disconnect connector (6).5. Remove bolt (4) and sensor (3). If necessary, remove the O-ring seal from sensor (3).6. Remove three bolts (2) and water lines group (1). 7. Remove bolt (9) from timing advance housing.8. Remove bolt (10) and support (11). 9. Remove the bolt and support (12). Remove the remaining ten bolts and the supports along the intake side of the cylinder head.10. Disconnect hose clamp (13) from the exhaust manifold. 11. Attach Tool (A) and fasten a hoist.12. Remove bolts (14) and remove the cylinder head. The weight of the cylinder head is approximately 172 kg (380 lb).13. Remove the head gasket and the water seals.
Do not put the cylinder head down on a flat surface. Direct injection nozzles extend out from the bottom surface of the cylinder head and will be damaged by the weight of the head.
Install Cylinder Head
1. Thoroughly clean the bottom surface of the cylinder head. Install a new head gasket and water seals. Do not use any adhesives. A new spacer plate gasket must be used when the cylinder head is installed. See the topic "Remove & Install Spacer Plate" in this module. 2. Attach Tool (D) and fasten a hoist.3. Install the cylinder head to the block. The weight of the cylinder head is approximately 172 kg (380 lb).
(1) Large bolts (3/4 inch). Put 6V-4876 Molycoat Paste Lubricant on bolt threads and between washer and underside of bolt heads. (2) Small bolts (3/8 inch). See Step 4h.4. Use the tightening sequence below to tighten the bolts that hold the cylinder head in position. a. Tighten bolts 1 through 14 in number sequence to 270 25 N m (200 20 lb ft).b. Tighten bolts 1 through 14 in number sequence to 470 20 N m (345 15 lb ft).c. Tighten bolts 1 through 14 in number sequence to 470 20 N m (345 15 lb ft).d. Install the rocker arm shafts for the engine valves and the remaining (3/4 in) bolts.e. Tighten bolts 15 through 26 in number sequence to 270 25 N m (200 20 lb ft).f. Tighten bolts 15 through 26 in number sequence to 450 20 N m (330 15 lb ft).g. Tighten bolts 15 through 26 in number sequence to 450 20 N m (330 15 lb ft).h. Tighten the thirteen small bolts (2) to a torque of 45 7 N m (33 5 lb ft). 5. Install support (12).6. Connect hose clamp (13) to exhaust manifold. 7. Install bolt (10) and support (11). Install the remaining ten bolts and the supports along the intake side of the cylinder head. Torque all twelve bolts (10) to 43 7 N m (32 5
Do not put the cylinder head down on a flat surface. Direct injection nozzles extend out from the bottom surface of the cylinder head and will be damaged by the weight of the head.
Install Cylinder Head
1. Thoroughly clean the bottom surface of the cylinder head. Install a new head gasket and water seals. Do not use any adhesives. A new spacer plate gasket must be used when the cylinder head is installed. See the topic "Remove & Install Spacer Plate" in this module. 2. Attach Tool (D) and fasten a hoist.3. Install the cylinder head to the block. The weight of the cylinder head is approximately 172 kg (380 lb).
(1) Large bolts (3/4 inch). Put 6V-4876 Molycoat Paste Lubricant on bolt threads and between washer and underside of bolt heads. (2) Small bolts (3/8 inch). See Step 4h.4. Use the tightening sequence below to tighten the bolts that hold the cylinder head in position. a. Tighten bolts 1 through 14 in number sequence to 270 25 N m (200 20 lb ft).b. Tighten bolts 1 through 14 in number sequence to 470 20 N m (345 15 lb ft).c. Tighten bolts 1 through 14 in number sequence to 470 20 N m (345 15 lb ft).d. Install the rocker arm shafts for the engine valves and the remaining (3/4 in) bolts.e. Tighten bolts 15 through 26 in number sequence to 270 25 N m (200 20 lb ft).f. Tighten bolts 15 through 26 in number sequence to 450 20 N m (330 15 lb ft).g. Tighten bolts 15 through 26 in number sequence to 450 20 N m (330 15 lb ft).h. Tighten the thirteen small bolts (2) to a torque of 45 7 N m (33 5 lb ft). 5. Install support (12).6. Connect hose clamp (13) to exhaust manifold. 7. Install bolt (10) and support (11). Install the remaining ten bolts and the supports along the intake side of the cylinder head. Torque all twelve bolts (10) to 43 7 N m (32 5