104303-3080 ZEXEL 9 400 616 457 BOSCH INJECTION-PUMP ASSEMBLY 9400616457 1043033080 5001510101

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 616 457 9400616457

ZEXEL 104303-3080 1043033080

TOYO-SHA 5001510101 5001510101

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Buy INJECTION-PUMP ASSEMBLY 104303-3080 zexel genuine, new aftermarket engine parts with delivery

Service parts 104303-3080 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 104300-3081

3. GOVERNOR

4. SUPPLY PUMP

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105141-1970

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 11.8{120}

13. NOZZLE-HOLDER 105071-0570

14. NOZZLE

105000-1010

15. NOZZLE SET

Include in #1:

104303-3080 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 616 457 9400616457

ZEXEL 104303-3080 1043033080

TOYO-SHA 5001510101 5001510101

Zexel num

Bosch num

Firm num

Name

104303-3080

9 400 616 457

5001510101 TOYO-SHA

INJECTION-PUMP ASSEMBLY
3S150 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 2.4 2.35 2.45

Rack position
After adjusting injection quantity. R=A

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 9.6

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 36.8 35.8 37.8

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.2+-0.5

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 10.8 9.8 11.8

Max. variation between cylinders % 0 -14 14

Fixing the lever *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Set the idle spring. (2)Set the governor spring.
----------

----------

Speed control lever angle

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

----------
a=16deg+-3deg b=33deg+-6deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=18deg+-3deg b=(38deg)

Timing setting

(1)Pump vertical direction (2)Position of camshaft's key groove at No 1 cylinder's beginning of injection (at full load) (3)B.T.D.C.: aa (at starting) (4)-
----------
aa=17deg
----------
a=(40deg)

Information:

(1) Distance dowels extend past end surface of cylinder block ... 8.0 0.5 mm (.31 .02 in)(2) Bore diameter in cylinder block for the cylinder liners ... 136.00 0.03 mm (5.354 .001 in)(3) Distance dowels extend past end surface of cylinder block ... 8.0 0.5 mm (.31 .02 in) (4) Spacer block.(5) Height of dowels above top surface of spacer block and cylinder block ... 8.00 0.03 mm (.315 .001 in)(6) Cylinder Liner. Make reference to the procedure for checking Cylinder Liner Projection in Testing And Adjusting Section of Service Manual Form No. SENR4964.Cylinder liner projection above the top surface of the spacer block must be ... 0.12 0.08 mm (.005 .003 in)Apply 7M7260 Liquid Gasket as required to cylinder liner shoulder and cylinder block face joint of all liners. (7) Depth plug is to be installed (from end surface of cylinder block to top of plug) ... 1.25 0.25 mm (.049 .010 in)(8) Diameter of camshaft bores ... 75.000 0.025 mm (2.9530 .0010 in)(9) Oil cooling jet assembly. Tighten bolt that holds oil cooling jet to ... 25 7 N m (18 5 1b ft)(10) Width of main bearing cap ... 175.00 0.02 mm (6.8898 .0008 in) Width in cylinder block for main bearing cap ... 175.000 0.018 mm (6.8898 .0007 in)(11) Distance from centerline of crankshaft bore to top surface of cylinder block ... 265.0 mm (10.43 in)The flatness across the top contact surface of the block must be within 0.05 mm (.002 in) for any 150 mm (5.9 in) section of the surface.(12) Distance from centerline of crankshaft to bottom surface of cylinder block ... 120.0 mm (4.72 in)(13) Main bearing cap bolts. Install as follows: Main bearing caps shall be assembled with the part number towards the right side. Caps are to be identified by stamped numbers 1 thru 7 located on the bottom unmachined surface.Main bearing cap bolts are to be lubricated on threads and washer face with SAE 30 oil or molylube. Tighten bolts to 95 5 N m (70 4 lb ft) plus 90 5° additional turn prior to machining. Tighten bolts simultaneously or tighten both bolts to 95 N m (70 lb ft) before turning the additional 90°.(14) Bore in cylinder block for seven main bearings ... 108.000 0.013 mm (4.2520 .0005 in) All main bearing bore measurements are to be made before caps are disassembled.