101603-8330 ZEXEL 9 400 619 684 BOSCH INJECTION-PUMP ASSEMBLY 9400619684 1016038330 8943933340

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 619 684 9400619684

ZEXEL 101603-8330 1016038330

ISUZU 8943933340 8943933340

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Buy INJECTION-PUMP ASSEMBLY 101603-8330 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-8330 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6210

3. GOVERNOR 105932-0310

4. SUPPLY PUMP

105210-6080

5. AUTOM. ADVANCE MECHANIS 105672-5250

6. COUPLING PLATE 105661-1140

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7740

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 16.2{165}/18.1{185}

13. NOZZLE-HOLDER 105030-4610

14. NOZZLE 105025-0080

15. NOZZLE SET

Include in #1:

101603-8330 as INJECTION-PUMP ASSEMBLY

Include in #2:

104742-1422 as _

Cross reference number

BOSCH 9 400 619 684 9400619684

ZEXEL 101603-8330 1016038330

ISUZU 8943933340 8943933340

Zexel num

Bosch num

Firm num

Name

101603-8330
101603-8331

9 400 619 684

8943933340 ISUZU

INJECTION-PUMP ASSEMBLY
6HH1-S * K

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 131424-4920

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 1-5-3-6- 2-4

Pre-stroke mm 4.7 4.65 4.75

Rack position
After adjusting injection quantity. R=A

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point -

Rack position 12.9

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 84 82.4 85.6

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 -

Rack position 9.6+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 9.4 8.1 10.7

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

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

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.9)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 84 83 85

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.15

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 94.5 91.3 97.7

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.2

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 75 71.8 78.2

Fixing the lever *

Timer adjustment

Pump speed r/min 905--

Advance angle deg. 0 0 0

Load 3/5

Remarks
Start

Timer adjustment_02

Pump speed r/min 855

Advance angle deg. 0.3

Load 3/5

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 1.5 1 2

Load 5/5

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 1110

Advance angle deg. 1.5 1 2

Load 3/5

Timer adjustment_05

Pump speed r/min 1450

Advance angle deg. 7 6.5 7.5

Load 5/5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)At delivery (at R = A, N = N1)
----------
T1=J58 N1=150r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt set position 'H' (3)Set the idle side stopper bolt at rack position = bb (at shipping).
----------
aa=35mm bb=(12.9)mm
----------
a=10deg+-5deg b=39deg+-3deg c=(14deg)

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=45mm
----------
a=12.5deg+-5deg b=40deg+-5deg

0000001501 I/P WITH LOAD PLUNGER ADJ

Plunger assembly number: PL (stamping: ST) 1. Adjustment procedures (1)Insert the pre-stroke adjusting shims L1 for each cylinder. (2)Adjust injection quantity.(max. var. bet. cyl. idling a1, full a2) (3)At basic point A, adjust so that the pre-stroke is L2. (4)Reconfirm the injection quantity.
----------
PL=131153-9020 ST=A769 L1=1mm L2=4.7+-0.05mm a1=+-14% a2=+-2.5%
----------

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=6deg
----------
a=(150deg)

Information:

1. Remove four bolts (1) that hold the oil pump to the engine block.2. Remove the oil pump. Be careful not to drop the oil pump drive gear.Install Oil Pump
1. Put the oil pump in position on the engine and install the bolts and washers. Make sure the idler gear teeth are correctly engaged with the crankshaft gear. The timing marks on the oil pump idler gear are for four cylinder engines with balancers.end by: a) install oil panDisassemble Oil Pump
start by:a) remove oil pump 1. Remove two bolts (1) and locks. Remove suction bell assembly (2). 2. Remove oil pump idler gear (3). 3. Use tool (A) to remove the idler gear bearing. 4. Remove the bolt and washer from the oil pump drive gear. Use tool (B) to remove the drive gear. Remove the key from the shaft. 5. Remove cover assembly (4). 6. Use tool (A) to remove the two bearings from the cover assembly. 7. Remove the two gears and shaft assemblies. Remove bolt (5). Remove valve assembly (6). 8. Use tool (A) to remove the two bearings from the cover assembly.Assemble Oil Pump
1. Use tool (A) to install two bearings each in the body assembly and the cover assembly. 2. Install valve assembly (2) with bolt (1). Install the two gears and shaft assemblies. Put oil on the two gears and make sure the gears move freely. 3. Install cover (3).4. Install the key on the shaft. Use the bolt and washer to install the oil pump drive gear. Make sure the key and gear groove are in alignment. 5. Use tool (A) to install the idler gear bearing.6. Install the oil pump idler gear. 7. Install bell assembly (4) with the two bolts and locks.end by:a) install oil pump