103662-3023 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1036623023

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 103662-3023 1036623023

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Service parts 103662-3023 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 103066-8400

3. GOVERNOR 105455-1042

4. SUPPLY PUMP 105235-1781

5. AUTOM. ADVANCE MECHANIS 105649-0010

6. COUPLING PLATE 105664-0200

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105111-4133

11. Nozzle and Holder 6162-12-3403

12. Open Pre:MPa(Kqf/cm2) 29.4{300}

13. NOZZLE-HOLDER 105041-7112

14. NOZZLE 105015-6640

15. NOZZLE SET

Include in #1:

101606-6671 as _

103662-3023 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 103662-3023 1036623023

Zexel num

Bosch num

Firm num

Name

103662-3023

INJECTION-PUMP ASSEMBLY
SA6D170 14BS PE4-8Z PE

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8130

Bosch type code EFEP215A

Nozzle 105780-0050

Bosch type code DN6TD119NP1T

Nozzle holder 105780-2090

Bosch type code EFEP215

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-4-1500

Overflow valve 133424-0420

Overflow valve opening pressure kPa 206 172 240

Overflow valve opening pressure kgf/cm2 2.1 1.75 2.45

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 3.8 3.75 3.85

Beginning of injection position
Drive 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 A

Rack position 17.7

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 483 478 488

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Boost pressure kPa 58.7 58.7

Boost pressure mmHg 440 440

Injection quantity adjustment_02

Adjusting point B

Rack position 9.7+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 51.7 46.7 56.7

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 650 650 650

Rack position 13.9

Boost pressure kPa 9.3 8 10.6

Boost pressure mmHg 70 60 80

Boost compensator adjustment_02

Pump speed r/min 650 650 650

Rack position 18.3

Boost pressure kPa 45.3 45.3 45.3

Boost pressure mmHg 340 340 340

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Minimum - maximum speed specification (2)Target notch: K (3)Stop lever's normal position setting: R1 (4)RACK LIMIT: RAL (5)Boost compensator stroke: BCL (6)Rack difference between N = N1 and N = N2 (7)Idle sub spring setting: L1.
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K=20 R1=19.9+0.5mm RAL=18.9+0.2mm BCL=4.4+-0.1mm N1=1050r/min N2=650r/min L1=8.6-0.5mm
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Speed control lever angle

F:Full speed
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----------
a=20deg+-5deg

0000000901

F:Full load I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting (3)Clearance is bb from where contacts inner stopper. (4)Actual measurement
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aa=80mm bb=(2)mm
----------
a=21deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb, pump speed cc (3)(Actual measurement) (4)(Actual measurement)
----------
aa=19.9+0.5mm bb=2-0.2mm cc=0r/min
----------

Information:

1. Remove bolts (1) and the washers that hold rocker shaft assembly (2) in position.2. Remove rocker shaft assembly (2). Remove the O-ring seal from the rear rocker arm support bracket.3. Put identification marks on push rods (3) as to their location in the engine. Remove the push rods.Install Rocker Shaft Assembly & Push Rods
1. Install push rods (1). Make sure they are in their original location in the engine and in position in the valve lifters.
Loosen the adjusting screws on the rocker arms. This will prevent a bent valve or push rod during installation of the rocker shaft assembly.
2. Install a new O-ring seal in the rear rocker arm support bracket. Put 2P2506 Thread Lubricant on all of the bolts that hold the rocker shaft assembly in position except for the bolt that goes through the rear rocker arm support bracket.3. Put rocker shaft assembly (2) in position on the engine. Make sure the dowels in the support bracket are in alignment with the dowel holes in the cylinder head. Make sure the rocker arms are engaged with the push rods.4. Install the bolts and washers that hold the rocker shaft assembly in position. Tighten them until they are finger tight.
3304 Engine Sequence
3306 Engine Sequence5. Tighten the bolts that hold the rocker shaft as follows:a. Tighten the bolts in number sequence to a torque of 156 N m (115 lb ft).b. Tighten the bolts in number sequence to a torque of 250 17 N m (185 13 lb ft).c. Tighten the bolts again in number sequence to a torque of 250 17 N m (185 13 lb ft).6. See "Valve Clearance Setting" in Testing & Adjusting. Make an adjustment to the valves so the intake valves have 0.38 mm (.015 in) clearance and the exhaust valves have 0.64 mm (.025 in) clearance. Tighten the locknuts for the adjusting screws to a torque of 29 7 N m (21 5 lb ft).End By:a. install valve cover