101603-2690 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016032690

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-2690 1016032690

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Cross reference number

ZEXEL 101603-2690 1016032690

Zexel num

Bosch num

Firm num

Name

101603-2690

INJECTION-PUMP ASSEMBLY

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 134424-0920

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-4-2-6- 3-5

Pre-stroke mm 3.45 3.42 3.48

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point A

Rack position 9.9

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 45.6 43.6 47.6

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 7.9+-0.5

Pump speed r/min 310 310 310

Average injection quantity mm3/st. 15 13.5 16.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 85 85 95

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 900--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 850

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1050

Advance angle deg. 1.5 1.2 1.8

Remarks
Finish

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)RACK LIMIT (4)Main spring setting (5)Set idle sub-spring
----------
K=15
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=12deg+-5deg b=19deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal (2)Rack position aa or less, pump speed bb
----------
aa=7.4mm bb=0r/min
----------
a=27deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(70deg)

Information:

(1) Inside diameter of rocker arm ... 19.063 to 19.101 mm (0.7505 to 0.7520 in) Rocker arm clearance on rocker shaft ... 0.030 to 0.089 mm (0.0012 to 0.0035 in)Maximum permissible clearance ... 0.13 mm (0.005 in)(2) Diameter of rocker shaft ... 19.012 to 19.037 mm (0.7485 to 0.7495 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 (0.310 to 0.312 in)(5) End play of camshaft (new) ... 0.10 to 0.41 mm (0.004 to 0.016 in) Maximum permissible end play (worn) ... 0.51 mm (0.020 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 engine. 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----U106654N and up. See General Information in Systems Operation for the engine serial number location.Outside diameter ... 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 mm to 0.33 mm (0.001 to 0.013 in)Inside diameter of thrust washer ... 44.45 mm (1.750 in)Thickness of thrust washer ... 5.47 to 5.54 mm (0.216 to 0.218 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 (0.187 to 0.190 in)Projection of thrust washer above cylinder block front face ... 0.66 to 0.79 mm (0.026 to 0.031 in)Current Models: Cylinder block recess depth for thrust washer ... 5.41 to 5.49 mm (0.213 to 0.216 in)Projection of thrust washer above cylinder block front face ... 0.00 to 0.13 mm (0.000 to 0.005 in)(8) Diameter of camshaft journals: No. 1 journal ... 50.710 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 topic Cylinder Block for camshaft bore specifications).(9) Tappet (valve lifter): Length ... 75.4063 mm (2.96875 in)Shank diameter ... 18.987 to 19.012 mm (0.7475 to 0.7485 in)Diameter of bore in block for tappet ... 19.050 to 19.083 mm (0.7500 to 0.7513 in)Running clearance between tappet and block ... 0.038 to 0.097 mm (0.0015 to 0.0038 in)Foot diameter ... 30.163 mm (1.1875 in) Camshaft lobe height:1. Measure base circle (C).2. Add lobe lift (A) to base circle measurement. Camshaft lobe lift (A) is ... 7.62 to 7.70