101603-8493 ZEXEL 9 400 615 269 BOSCH INJECTION-PUMP ASSEMBLY 9400615269 1016038493 8943957513

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 269 9400615269

ZEXEL 101603-8493 1016038493

ISUZU 8943957513 8943957513

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104741-5402 as _

Cross reference number

BOSCH 9 400 615 269 9400615269

ZEXEL 101603-8493 1016038493

ISUZU 8943957513 8943957513

Zexel num

Bosch num

Firm num

Name

101603-8493

9 400 615 269

8943957513 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 13

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 86.5 84.9 88.1

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(13)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 86.5 85.5 87.5

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. 95.5 92.3 98.7

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.25

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 77.5 74.3 80.7

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.
----------
T1=K09
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=14deg+-5deg b=40deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=46.5mm
----------
a=34.5deg+-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)At rack position = bb
----------
aa=6deg bb=R1(13)mm
----------
a=(150deg)

Information:

(1) Thickness of top plate ... .338 .001 in.(8.59 0.03 mm) Thickness of gasket that is placed between top plate and cylinder block ... .008 .001 in.(0.20 0.03 mm)Height of liner over top plate, under installation pressure ... .005 .003 in.(0.13 0.08 mm)(2) Height of dowels above top surface of cylinder block ... .73 in.(18.5 mm)(3) Dimension (new) from centerline of crankshaft bearing bore to top of block (top deck) ... 16.750 .006 in.(425.45 0.15 mm)(4) Bore in block for camshaft bearings ... 3.0250 .0007 in.(76.835 0.018 mm)(5) Bore in the block for the main bearings: standard, original size (new) ... 5.1138 .0005 in.(129.891 0.013 mm).025 in. (0.64 mm) larger than original size ... 5.1388 .0005 in.(130.526 0.013 mm)(6) Distance from front or rear face of cylinder block to end of dowels ... .75 in.(19.1 mm)(7) Width of main bearing cap ... 8.5000 .0005 in.(215.900 0.013 mm) Width of block for main bearing cap ... 8.5000 .0005 in.(215.900 0.013 mm)Clearance between main bearing cap and cylinder block ... .001 in.(0.03 mm) tight to ... .001 in.(0.03 mm) loose
Tightening Procedure For Main Bearings(8) Torque for the bolts that hold the caps for the main bearings: Install the main bearing caps with the marks (arrow) toward the front of the engine. Install each cap in the correct position by putting the number stamped on the bottom of the cap toward the corresponding number on the cylinder block.a. Put engine oil on the threads of the bolts.b. Tighten the bolts first on the tab side of the cap to ... 190 10 lb. ft.(260 14 N m)c. Tighten the bolts on the opposite side to ... 190 10 lb. ft.(260 14 N m)d. Put a mark on each bolt and cap as shown.e. Tighten the bolts on the opposite side, from the mark ... 120°f. Tighten the bolts on the tab side of the cap, from the mark ... 120°(9) Dimension (new) from centerline of crankshaft bearing bore to bottom of block (pan rails) ... 6.500 .004 in.(165.10 0.10 mm) (10) Put 9S3264 Pipe Sealant on threads of 14 plugs before installation in the cylinder block.(11) Torque for bolts holding oil jet cooling tubes (later engines) ... 18 5 lb. ft.(24 7 N m)