104303-2300 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1043032300 5156013441

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104303-2300 1043032300

ISUZU 5156013441 5156013441

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Cross reference number

ZEXEL 104303-2300 1043032300

ISUZU 5156013441 5156013441

Zexel num

Bosch num

Firm num

Name

104303-2300

5156013441 ISUZU

INJECTION-PUMP ASSEMBLY
3AG1 * 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

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 1-3-2

Pre-stroke mm 2.1 2.05 2.15

Beginning of injection position
Drive side NO.1

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

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

Injection quantity adjustment

Adjusting point A

Rack position 10.7

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 32.2 31.2 33.2

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 7.7+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 7.5 6.5 8.5

Max. variation between cylinders % 0 -14 14

Fixing the lever *

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

Injection quantity adjustment_03

Adjusting point C

Rack position 13+1

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 35.6 35.6

Fixing the lever *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Set the idle spring. (2)Main spring setting (3)Rack difference between N = N1 and N = N2 (4)Rack difference between N = N3 and N = N4
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N1=1300r/min N2=1000r/min N3=1300r/min N4=450r/min
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Speed control lever angle

F:Full speed I:Idle
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----------
a=7deg+-3deg b=35deg+-6deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark '00' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=20deg
----------
a=(110deg)

Information:

Cylinder Head And Valve Components
Check cylinder head for cracks before reconditioning.Flatness of the cylinder head should be within .006 in. (0.15 mm) total, and a maximum of .003 in. (0.08 mm) for any 6 in. (152.4 mm) span. A maximum stock removal of .010 in. (0.25 mm) is permissible when resurfacing the head.Always check the thickness of a cylinder head before resurfacing. The cylinder head may have been resurfaced before and would not have enough stock to be resurfaced again.To check the thickness of a cylinder head, measure through the fuel injection nozzle holes at each end of the cylinder head. For the correct thickness of the cylinder head, see the topic CYLINDER HEAD in the SPECIFICATIONS.The exhaust valve seats have replaceable inserts. To remove, use the 8S7170 Valve Seat Insert Puller Group.
REMOVING EXHAUST VALVE SEAT INSERTFreeze the exhaust valve seat inserts or use the 8S7170 Valve Seat Insert Puller Group to install inserts into head. Be sure bores are clean, free of burrs, and the insert has a good press fit into the bore.After inserts are installed, grind the seat face of the insert to be sure it is flat, has the correct angle, and is in alignment with the bore in the valve guide. For specifications, see VALVE GRINDING SPECIFICATIONS CHART. Replace exhaust valve seat inserts when valve seat width or valve head-to-cylinder head face can not be machined to the correct specification. For specifications, see VALVE GRINDING SPECIFICATIONS CHART.A 2N8943 Valve Seat Insert for the intake valve is available. This insert can be used in the repair of cylinder heads which have an intake valve seat with damage. Before, damage to an intake valve seat made replacement of the cylinder head assembly necessary.To use a 2N8943 Valve Seat Insert, the inlet port of the cylinder head must be machined to a diameter of 2.1470 .0005 in. (54.534 0.013 mm) and to a depth of .442 .002 in. (11.23 0.05 mm).To install a 2N8943 Valve Seat Insert into the cylinder head, freeze the insert or use a 2P2343 Extractor with the 8S7170 Valve Seat Insert Puller Group. After an insert is installed, grind the seat face of the insert to be sure it is flat, has the correct angle, and is in alignment with the bore in the valve guide. For specifications, see VALVE GRINDING SPECIFICATIONS CHART.Clean valve guides of all carbon and oil, using the 5P5176 Brush and a solvent.The valve guides are cast in the cylinder heads. Check each valve guide bore size 3/4 in. (19.1 mm) deep from each end. The bore size is .3745 .0005 in. (9.512 0.013 mm) and the maximum size worn is .3760 in. (9.550 mm). Valve guides worn more than the maximum wear size, can be restored to original tolerances through knurling.Use the 5P3536 Valve Guide Gauge Group to check the bore of the valve guides. Special Instructions GMG02562 gives complete and detailed instructions for use of the 5P3536 Valve Guide Gauge