Information injection-pump assembly
ZEXEL
101601-4391
1016014391
ISUZU
5156008804
5156008804
Rating:
Cross reference number
ZEXEL
101601-4391
1016014391
ISUZU
5156008804
5156008804
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 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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.6
3.55
3.65
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
10.9
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
60.3
58.8
61.8
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
9.5+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
8.7
7.4
10
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(10.9)
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
60.3
59.3
61.3
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
11+-0.5
Pump speed
r/min
1600
1600
1600
Average injection quantity
mm3/st.
65.2
63.6
66.8
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
10.85+-0
.5
Pump speed
r/min
1300
1300
1300
Average injection quantity
mm3/st.
64
62.4
65.6
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
D
Rack position
R1(10.9)
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
46.9
45.3
48.5
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1000
Advance angle
deg.
0.3
Timer adjustment_02
Pump speed
r/min
1050
Advance angle
deg.
0.7
Timer adjustment_03
Pump speed
r/min
1300
Advance angle
deg.
1.8
1.3
2.3
Timer adjustment_04
Pump speed
r/min
1600
Advance angle
deg.
4
3.5
4.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT: RAL
----------
T1=19 RAL=13.6+0.2mm
----------
----------
T1=19 RAL=13.6+0.2mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=40deg+-5deg b=39deg+-3deg
----------
----------
a=40deg+-5deg b=39deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=25deg+-5deg b=40deg+-5deg
----------
----------
a=25deg+-5deg b=40deg+-5deg
Information:
START BY:a. remove alternator and mounting groupb. remove water temperature regulator and manifold1. Drain the coolant from the engine. 2. Loosen the clamps on breather tube (1), and pull it back for clearance. 3. Remove bolt (2) from the cover on the side of the cylinder block. 4. Remove the three bolts that hold cover (3) to the water pump. Remove cover (3) from the water pump. 5. Remove the two bolts, and remove elbow (4) from bonnet (5). Remove the two bolts, and remove bonnet (5) from the water pump. It is not necessary to remove bolts (6). These bolts only hold the cover to the timing gear cover.6. Remove six long bolts (7) that hold the water pump to the timing gear cover. Remove water pump (8).Install Water Pump
1. Check the O-ring seals and gaskets, and make replacements if needed. 2. Make sure O-ring seal (1) is in position on the water pump. Put water pump (2) into position in the timing gear cover. Install the bolts that hold the water pump in place. 3. Make sure the gaskets are in place. Connect bonnet (3) to the water pump. Connect elbow (4) to the bonnet. 4. Make sure O-ring seal (5) is in position, and install cover (6) on the water pump. 5. Install bolt (7) on the cover on the side of the engine. 6. Put breather tube (8) in position, and install the clamps that hold it.7. Fill the cooling system to the correct level. See the Maintenance Guide.Disassemble Water Pump
START BY:a. remove water pump The water pump seal can be replaced without removing the water pump from the engine.An intermittent leakage of a small amount of coolant from the hole in the water pump housing is not an indication of a water pump seal failure. This is required to provide lubrication for the seal. Replace the water pump seal only if a large amount of leakage or a constant flow of coolant is observed draining from the water pump housing.1. Remove O-ring seal (1) from the adapter.2. Remove adapter (2) from the housing. Remove the O-ring seal from the outside diameter of the adapter.3. Remove bolt (3) and the retainer that hold the impeller on the shaft. 4. Use tooling (A) to remove impeller (4) from the shaft. 5. Remove the spring and seal (5) from the shaft. 6. Remove four bolts (7) from retainer (6) that hold the shaft assembly to the pump housing.7. Remove O-ring seal (8) from the housing. 8. Remove gear and shaft assembly (10) from the housing.9. Remove bolt (9) and the retainer from the shaft assembly. 10. Use a press to remove the shaft assembly from gear (11). Remove the retainer from the shaft assembly. 11. Remove bearing (13), spacer (14) and bearing (12) from the shaft. 12. Remove lip-type seal (15) from the housing.13. Turn the housing over, and remove ceramic ring (16) and the seal.Assemble Water Pump
1. Use 6V1541 Quick Cure Primer and clean shaft
1. Check the O-ring seals and gaskets, and make replacements if needed. 2. Make sure O-ring seal (1) is in position on the water pump. Put water pump (2) into position in the timing gear cover. Install the bolts that hold the water pump in place. 3. Make sure the gaskets are in place. Connect bonnet (3) to the water pump. Connect elbow (4) to the bonnet. 4. Make sure O-ring seal (5) is in position, and install cover (6) on the water pump. 5. Install bolt (7) on the cover on the side of the engine. 6. Put breather tube (8) in position, and install the clamps that hold it.7. Fill the cooling system to the correct level. See the Maintenance Guide.Disassemble Water Pump
START BY:a. remove water pump The water pump seal can be replaced without removing the water pump from the engine.An intermittent leakage of a small amount of coolant from the hole in the water pump housing is not an indication of a water pump seal failure. This is required to provide lubrication for the seal. Replace the water pump seal only if a large amount of leakage or a constant flow of coolant is observed draining from the water pump housing.1. Remove O-ring seal (1) from the adapter.2. Remove adapter (2) from the housing. Remove the O-ring seal from the outside diameter of the adapter.3. Remove bolt (3) and the retainer that hold the impeller on the shaft. 4. Use tooling (A) to remove impeller (4) from the shaft. 5. Remove the spring and seal (5) from the shaft. 6. Remove four bolts (7) from retainer (6) that hold the shaft assembly to the pump housing.7. Remove O-ring seal (8) from the housing. 8. Remove gear and shaft assembly (10) from the housing.9. Remove bolt (9) and the retainer from the shaft assembly. 10. Use a press to remove the shaft assembly from gear (11). Remove the retainer from the shaft assembly. 11. Remove bearing (13), spacer (14) and bearing (12) from the shaft. 12. Remove lip-type seal (15) from the housing.13. Turn the housing over, and remove ceramic ring (16) and the seal.Assemble Water Pump
1. Use 6V1541 Quick Cure Primer and clean shaft