104700-9111 ZEXEL F 01G 09W 012 BOSCH INJECTION-PUMP ASSEMBLY f01g09w012 1047009111 3310442300

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 01G 09W 012 f01g09w012

ZEXEL 104700-9111 1047009111

HYUNDAI 3310442300 3310442300

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Components :

0.	INJECTION-PUMP ASSEMBLY	104700-9111
1.	_
2.	FUEL INJECTION PUMP	104600-9111
3.	NUMBER PLATE	148643-4200
4.	_
5.	CAPSULE
6.	ADJUSTING DEVICE
7.	NOZZLE AND HOLDER ASSY
8.	Nozzle and Holder
9.	Open Pre:MPa(Kqf/cm2)
10.	NOZZLE-HOLDER
11.	NOZZLE

Scheme ###:

1/6.	[1]	146601-0700	PACKING RING
6.	[1]	146100-0120	SUPPLY PUMP
9.	[1]	148103-0400	COVER
10.	[2]	139104-0000	FLAT-HEAD SCREW
12.	[1]	148200-0520	DRIVE SHAFT
17.	[1]	146204-0000	PLAIN WASHER
20.	[1]	148210-0120	ROLLER SET
24.	[1]	146303-0000	BEARING PIN
25.	[1]	146304-0000	BEARING PIN
26.	[1]	146305-0000	CLAMPING BAND
27.	[1]	146205-0000	SLOTTED WASHER
29.	[1]	146220-4320	CAM PLATE
30.	[1]	146600-0800	O-RING
31.	[1]	146300-1900	PUMP PLUNGER
32.	[1]	146301-0000	SLIDING PIECE
33.	[1]	146603-1100	SHIM
34.	[1]	146306-1800	COMPRESSION SPRING
34B.	[1]	146306-2100	COMPRESSION SPRING
35/1.	[0]	146603-0700	SHIM D17.5&7.5T0.60
35/1.	[0]	146603-0800	SHIM D17.5&7.5T0.70
35/1.	[0]	146603-0900	SHIM D17.5&7.5T0.90
35/1.	[0]	146603-1000	SHIM D17.5&7.5T1.00
35/1.	[0]	146603-1100	SHIM D17.5&7.5T1.20
35/1.	[0]	146603-3600	SHIM D17.5&7.5T2.40
36.	[1]	146600-0800	O-RING
37.	[1]	479766-2620	TIMER PISTON SENSOR
38.	[2]	010206-2040	HEX-SOCKET-HEAD CAP SCREW
39.	[1]	146310-0100	COVER
40.	[2]	146620-5000	BLEEDER SCREW
43.	[1]	146230-0000	SHIM
44.	[1]	146230-0100	PLAIN WASHER
45.	[1]	146231-0001	SLOTTED WASHER
47.	[2]	146233-0000	SLOTTED WASHER
48/1.	[1]	146603-0000	SHIM D17.0&5.2T0.50
48/1.	[1]	146603-0100	SHIM D17.0&5.2T0.80
48/1.	[1]	146603-0200	SHIM D17.0&5.2T1.00
48/1.	[1]	146603-0300	SHIM D17.0&5.2T1.20
48/1.	[1]	146603-0400	SHIM D17.0&5.2T1.50
48/1.	[1]	146603-0500	SHIM D17.0&5.2T1.80
48/1.	[1]	146603-0600	SHIM D17.0&5.2T2.00
48/1.	[1]	146690-1400	SHIM D17&5.2T0.9
48/1.	[1]	146690-1500	SHIM D17&5.2T1.1
48/1.	[1]	146690-1600	SHIM D17&5.2T1.3
48/1.	[1]	146690-1700	SHIM D17&5.2T1.4
48/1.	[1]	146690-1800	SHIM D17&5.2T1.6
48/1.	[1]	146690-1900	SHIM D17&5.2T1.7
48/1.	[1]	146690-5800	SHIM D17&5.2T2.1
48/1.	[1]	146690-5900	SHIM D17&5.2T2.2
48/1.	[1]	146690-6000	SHIM D17&5.2T2.3
48/1.	[1]	146690-6100	SHIM D17&5.2T2.4
48/1.	[1]	146690-6200	SHIM D17&5.2T2.5
48/1.	[1]	146690-6300	SHIM D17&5.2T2.6
48/1.	[1]	146690-6400	SHIM D17&5.2T2.7
48/1.	[1]	146690-6500	SHIM D17&5.2T2.8
48/1.	[1]	146690-6600	SHIM D17&5.2T2.9
48/1.	[1]	146690-6700	SHIM D17&5.2T3.0
48/1.	[1]	146690-6800	SHIM D17&5.2T3.1
48/1.	[1]	146690-6900	SHIM D17&5.2T3.2
48/1.	[1]	146690-7000	SHIM D17&5.2T3.3
48/1.	[1]	146690-7100	SHIM D17&5.2T3.4
48/1.	[1]	146690-7200	SHIM D17&5.2T0.4
48/1.	[1]	146690-7300	SHIM D17&5.2T0.6
48/1.	[1]	146690-7400	SHIM D17&5.2T0.7
48/1.	[1]	146690-7500	SHIM D17&5.2T1.9
48/1.	[1]	146690-7800	SHIM D17&5.2T0.2
49.	[2]	146234-0600	GUIDE PIN
50.	[1]	146403-8720	HYDRAULIC HEAD
50.	[1]	146403-8720	HYDRAULIC HEAD
50.	[1]	146403-8720	HYDRAULIC HEAD
51.	[1]	146600-0000	O-RING
52/1.	[1]	146420-0000	SHIM D9.5&3.0T1.90
52/1.	[1]	146420-0100	SHIM D9.5&3.0T1.92
52/1.	[1]	146420-0200	SHIM D9.5&3.0T1.94
52/1.	[1]	146420-0300	SHIM D9.5&3.0T1.96
52/1.	[1]	146420-0400	SHIM D9.5&3.0T1.98
52/1.	[1]	146420-0500	SHIM D9.5&3.0T2.00
52/1.	[1]	146420-0600	SHIM D9.5&3.0T2.02
52/1.	[1]	146420-0700	SHIM D9.5&3.0T2.04
52/1.	[1]	146420-0800	SHIM D9.5&3.0T2.06
52/1.	[1]	146420-0900	SHIM D9.5&3.0T2.08
52/1.	[1]	146420-1000	SHIM D9.5&3.0T2.10
52/1.	[1]	146420-1100	SHIM D9.5&3.0T2.12
52/1.	[1]	146420-1200	SHIM D9.5&3.0T2.14
52/1.	[1]	146420-1300	SHIM D9.5&3.0T2.16
52/1.	[1]	146420-1400	SHIM D9.5&3.0T2.18
52/1.	[1]	146420-1500	SHIM D9.5&3.0T2.20
52/1.	[1]	146420-1600	SHIM D9.5&3.0T2.22
52/1.	[1]	146420-1700	SHIM D9.5&3.0T2.24
52/1.	[1]	146420-1800	SHIM D9.5&3.0T2.26
52/1.	[1]	146420-1900	SHIM D9.5&3.0T2.28
52/1.	[1]	146420-2000	SHIM D9.5&3.0T2.30
52/1.	[1]	146420-2100	SHIM D9.5&3.0T2.32
52/1.	[1]	146420-2200	SHIM D9.5&3.0T2.34
52/1.	[1]	146420-2300	SHIM D9.5&3.0T2.36
52/1.	[1]	146420-2400	SHIM D9.5&3.0T2.38
52/1.	[1]	146420-2500	SHIM D9.5&3.0T2.40
52/1.	[1]	146420-2600	SHIM D9.5&3.0T2.42
52/1.	[1]	146420-2700	SHIM D9.5&3.0T2.44
52/1.	[1]	146420-2800	SHIM D9.5&3.0T2.46
52/1.	[1]	146420-2900	SHIM D9.5&3.0T2.48
52/1.	[1]	146420-3000	SHIM D9.5&3.0T2.50
52/1.	[1]	146420-3100	SHIM D9.5&3.0T2.52
52/1.	[1]	146420-3200	SHIM D9.5&3.0T2.54
52/1.	[1]	146420-3300	SHIM D9.5&3.0T2.56
52/1.	[1]	146420-3400	SHIM D9.5&3.0T2.58
52/1.	[1]	146420-3500	SHIM D9.5&3.0T2.60
52/1.	[1]	146420-3600	SHIM D9.5&3.0T2.62
52/1.	[1]	146420-3700	SHIM D9.5&3.0T2.64
52/1.	[1]	146420-3800	SHIM D9.5&3.0T2.66
52/1.	[1]	146420-3900	SHIM D9.5&3.0T2.68
52/1.	[1]	146420-4000	SHIM D9.5&3.0T2.70
52/1.	[1]	146420-4100	SHIM D9.5&3.0T2.72
52/1.	[1]	146420-4200	SHIM D9.5&3.0T2.74
52/1.	[1]	146420-4300	SHIM D9.5&3.0T2.76
52/1.	[1]	146420-4400	SHIM D9.5&3.0T2.78
52/1.	[1]	146420-4500	SHIM D9.5&3.0T2.80
52/1.	[1]	146420-4600	SHIM D9.5&3.0T2.82
52/1.	[1]	146420-4700	SHIM D9.5&3.0T2.84
52/1.	[1]	146420-4800	SHIM D9.5&3.0T2.86
52/1.	[1]	146420-4900	SHIM D9.5&3.0T2.88
52/1.	[1]	146420-5000	SHIM D9.5&3.0T2.90
52/1.	[1]	146420-5100	SHIM D9.5&3.0T1.74
52/1.	[1]	146420-5200	SHIM D9.5&3.0T1.76
52/1.	[1]	146420-5300	SHIM D9.5&3.0T1.78
52/1.	[1]	146420-5400	SHIM D9.5&3.0T1.80
52/1.	[1]	146420-5500	SHIM D9.5&3.0T1.82
52/1.	[1]	146420-5600	SHIM D9.5&3.0T1.84
52/1.	[1]	146420-5700	SHIM D9.5&3.0T1.86
52/1.	[1]	146420-5800	SHIM D9.5&3.0T1.88
54.	[4]	146433-0100	GASKET
55.	[4]	146430-0320	DELIVERY-VALVE ASSEMBLY VE4
56.	[4]	146432-0801	COMPRESSION SPRING
58.	[4]	146440-0120	FITTING
60.	[3]	139106-0100	FLAT-HEAD SCREW
123.	[1]	146620-8800	FLAT-HEAD SCREW
130.	[1]	146421-1020	CAPSULE
130/2.	[1]	139508-0200	GASKET
130/3.	[1]	146422-0300	BLEEDER SCREW
130/4.	[1]	146600-0500	O-RING
133.	[1]	146600-0600	O-RING
134.	[1]	146600-0700	O-RING
135.	[1]	146110-3220	CONTROL VALVE
135/5.	[1]	146114-0000	SPRING WASHER
136.	[1]	148120-0020	OVER FLOW VALVE
137.	[3]	139512-0500	GASKET
138.	[1]	146669-5822	INLET UNION
158.	[1]	146614-6900	SPACER BUSHING
200.	[1]	146206-0100	COILED SPRING
205.	[1]	029470-4030	WOODRUFF KEY
230.	[1]	148613-6621	BRACKET
236.	[1]	146620-2700	HEX-SOCKET-HEAD CAP SCREW
237.	[1]	146620-0200	HEX-SOCKET-HEAD CAP SCREW
240.	[1]	146688-0120	PULLING ELECTROMAGNET
240/8.	[1]	146600-1700	O-RING
243.	[1]	146621-1000	UNION NUT
245.	[3]	139512-0500	GASKET
246.	[1]	146125-0700	EYE BOLT
247.	[1]	146669-6822	INLET UNION
248.	[1]	146614-0200	SPACER BUSHING
275.	[1]	148612-1400	BRACKET
276.	[2]	010010-2840	BLEEDER SCREW
278.	[2]	146616-8501	SPACER BUSHING
282.	[1]	139006-4600	BLEEDER SCREW
504/1.	[1]	146649-4500	RESISTER NO. 1 0.18K:OHM
504/1.	[1]	146649-4600	RESISTER NO. 2 0.30K:OHM
504/1.	[1]	146649-4700	RESISTER NO. 3 0.43K:OHM
504/1.	[1]	146649-4800	RESISTER NO. 4 0.62K:OHM
504/1.	[1]	146649-4900	RESISTER NO. 5 0.82K:OHM
504/1.	[1]	146649-5000	RESISTER NO. 6 1.10K:OHM
504/1.	[1]	146649-5100	RESISTER NO. 7 1.50K:OHM
504/1.	[1]	146649-5200	RESISTER NO. 8 2.00K:OHM
504/1.	[1]	146649-5300	RESISTER NO. 9 2.70K:OHM
504/1.	[1]	146649-5400	RESISTER NO.10 3.90K:OHM
504/1.	[1]	146649-5500	RESISTER NO.11 5.60K:OHM
504/1.	[1]	146649-5600	RESISTER NO.12 8.20K:OHM
504/1.	[1]	146649-5700	RESISTER NO.13 15.00K:OHM
505.	[1]	148530-4221	GOVERNOR;ELECTRIC
506.	[3]	146620-8900	FLAT-HEAD SCREW
515.	[1]	106144-1071	TIMING CONTROL VALVE
515/7.	[1]	161440-3800	O-RING
515/8.	[1]	161440-3700	O-RING
516.	[2]	010206-1440	HEX-SOCKET-HEAD CAP SCREW
530.	[4]	148650-0000	BINDER
531.	[1]	479766-2321	PULSE GENERATOR
531/6.	[1]	479773-6500	O-RING
535.	[1]	148650-0300	TAPE 1600MM
536.	[1]	148650-3700	TUBE
551.	[1]	146659-9502	CLAMPING BAND
552.	[1]	146622-2200	LOCKING WASHER
553.	[1]	146622-2100	HEX-SOCKET-HEAD CAP SCREW
555.	[1]	148852-0900	COVER
556.	[1]	148852-1000	COVER
800S.	[1]	148009-0620	PUMP HOUSING
800S/1/6.	[1]	146601-0700	PACKING RING
804S.	[1]	146232-0720	COMPRESSION SPRING
810S.	[1]	146600-4620	REPAIR SET
821S.	[1]	146210-5720	ROLLER SET
878S.	[1]	148600-1300	SEAL RING
906.	[1]	148643-4200	NAMEPLATE

Include in #2:

104700-9111 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH F 01G 09W 012 f01g09w012

ZEXEL 104700-9111 1047009111

HYUNDAI 3310442300 3310442300

Zexel num

Bosch num

Firm num

Name

104700-9111
104700-9112

F 01G 09W 012

3310442300 HYUNDAI

INJECTION-PUMP ASSEMBLY
4D56TCI * K 11CL INJECTION PUMP ASSY COVEC 4 COVEC

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113orSAEJ967d

Test oil temperature degC 45 45 50

Nozzle 105780-0060

Bosch type code NP-DN0SD1510

Nozzle holder 105780-2150

Opening pressure MPa 13 13 13.3

Opening pressure kgf/cm2 133 133 136

Injection pipe 157805-7320

Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-450

Joint assembly 157641-4720

Tube assembly 157641-4020

Transfer pump pressure kPa 20 20 20

Transfer pump pressure kgf/cm2 0.2 0.2 0.2

Direction of rotation (viewed from drive side)
Right R

Governor adjustment

Pump speed r/min 1000 1000 1000

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Pump chamber pressure kPa 598 569 627

Pump chamber pressure kgf/cm2 6.1 5.8 6.4

Basic *

Governor adjustment_02

Pump speed r/min 100 100 100

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Pump chamber pressure kPa 294 294

Pump chamber pressure kgf/cm2 3 3

Governor adjustment_03

Pump speed r/min 1000 1000 1000

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Pump chamber pressure kPa 598 559 637

Pump chamber pressure kgf/cm2 6.1 5.7 6.5

Governor adjustment_04

Pump speed r/min 2000 2000 2000

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Pump chamber pressure kPa 735 686 784

Pump chamber pressure kgf/cm2 7.5 7 8

Boost compensator adjustment

Pump speed r/min 1000 1000 1000

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Timer stroke mm 7.7 7.5 7.9

Basic *

Boost compensator adjustment_02

Pump speed r/min 100 100 100

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Timer stroke mm 1.8 0.3 3.3

Boost compensator adjustment_03

Pump speed r/min 350 350 350

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Timer stroke mm 5.2 3.1 7.3

Boost compensator adjustment_04

Pump speed r/min 1000 1000 1000

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Timer stroke mm 7.7 7.4 8

Boost compensator adjustment_05

Pump speed r/min 1000 1000 1000

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Timer stroke mm 4 1.9 6.1

Boost compensator adjustment_06

Pump speed r/min 2000 2000 2000

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Timer stroke mm 9.75 9.3 10.2

Boost compensator adjustment_07

Pump speed r/min 2000 2000 2000

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Timer stroke mm 0 0 0

Timer adjustment

Pump speed r/min 1000 1000 1000

TCV duty (%) F TCV 60Hz % 0 0 0

U alpha soll V 2.7 2.7 2.7

Vtps V 0.51 0.382 0.638

Basic *

Timer adjustment_02

Pump speed r/min 1000 1000 1000

TCV duty (%) F TCV 60Hz % 0 0 0

U alpha soll V 2.7 2.7 2.7

Vtps V 0.51 0.382 0.638

Timer adjustment_03

Pump speed r/min 1000 1000 1000

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Vtps V 1.925 1.702 2.148

Speed control lever angle

Pump speed r/min 1000 1000 1000

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Overflow quantity cm3/min 680 550 810

0000000901

Pump speed r/min 1250 1250 1250

U alpha soll + dU alpha soll V 2.83 2.83 2.83

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 68.8 68.3 69.3

Difference in delivery mm3/st. 3.5

Basic *

_02

Pump speed r/min 375 375 375

U alpha soll + dU alpha soll V 1.9 1.9 1.9

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 12.8 9.8 15.8

Difference in delivery mm3/st. 2.5

Basic *

Remarks
Confirmation of difference in delivery

_03

Pump speed r/min 2575 2575 2575

U alpha soll + dU alpha soll V 1.8 1.8 1.8

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 18.3 15.8 20.8

Difference in delivery mm3/st. 5.5

Basic *

Remarks
Confirmation of difference in delivery

_04

Pump speed r/min 100 100 100

U alpha soll + dU alpha soll V 2.9 2.9 2.9

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 51.4 41.4 61.4

_05

Pump speed r/min 375 375 375

U alpha soll + dU alpha soll V 1.9 1.9 1.9

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 12.8 9.8 15.8

_06

Pump speed r/min 500 500 500

U alpha soll + dU alpha soll V 2.46 2.46 2.46

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 45.6 43.1 48.1

_07

Pump speed r/min 750 750 750

U alpha soll + dU alpha soll V 2.68 2.68 2.68

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 60.1 57.6 62.6

_08

Pump speed r/min 1000 1000 1000

U alpha soll + dU alpha soll V 2.84 2.84 2.84

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 70.7 68.2 73.2

_09

Pump speed r/min 1250 1250 1250

U alpha soll + dU alpha soll V 2.83 2.83 2.83

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 68.8 67.8 69.8

_10

Pump speed r/min 1500 1500 1500

U alpha soll + dU alpha soll V 2.78 2.78 2.78

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 66.5 64 69

_11

Pump speed r/min 1750 1750 1750

U alpha soll + dU alpha soll V 2.72 2.72 2.72

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 61.7 59.2 64.2

_12

Pump speed r/min 2000 2000 2000

U alpha soll + dU alpha soll V 2.66 2.66 2.66

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 59 56.5 61.5

_13

Pump speed r/min 2575 2575 2575

U alpha soll + dU alpha soll V 1.8 1.8 1.8

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 18.3 15.8 20.8

_14

Pump speed r/min 2575 2575 2575

U alpha soll + dU alpha soll V 1 1 1

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 3

Stop lever angle

Pump speed r/min 2000 2000 2000

U alpha soll + dU alpha soll V 2.66 2.66 2.66

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity cm3/min 0 0 0

0000001101

Pump speed r/min 200 200 200

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Speed output
N=Measure the actual speed. r/min N+-8

0000001201

Pump speed r/min 1250 1250 1250

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.73 2.73 2.73

Temperature output
Measure T = actual output temperature degC T+-5

0000001301

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

K dimension mm 3.3 3.2 3.4

KF dimension mm 5.9 5.8 6

Pre-stroke mm 0.1 0.08 0.12

Test data Ex:

Injection timing adjustment Comp. resistor/voltage

Compensation resistance/compensation voltage comparison A = Compensation resistor number B= Compensation resistance C = Compensation voltage delta U alpha soll
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0000001601 HARNESS & CONNECTOR

T.C.V. connector assembly specification (1)Ensure the GE cable is not twisted at section A. (2)Refer to diagram for direction of connector B. (3)Route the TCV harnes C in the direction indicated by the arrows in the figure and install the connector.
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0000001701 HARNESS & CONNECTOR

Harness position specification (1)Where the connector side's harness is pulled out, position the protective tube at the connector side so that lead wire exposure is the minimum. (2)Fix the harness using clips to the dimensions shown in the figure. (3)Cut the binder leaving no more than L1 excess. A = GE, TCV, Q adjustment B=NP,FCV C=TPS E = binder
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a=(75deg) L1=Max.2mm L2=110+-10mm L3=80+-10mm L4=70+-10mm

0000001801 HARNESS & CONNECTOR

Corrugated tube assembly specification (1)Where the pump sensor side and connector side harness come out, attach protective tube to the sensor side and the connector side (except for the FCV grommet position) so that the lead wires are not exposed or visible. (2)Align the end of the corrugated tube with clip A and fix it using black vinyl tape (L1, L2). (3)Confirm that the dimension to the end of the corrugated tube C is L3, and fix it using black vinyl tape (L4, L5). (4)Refer to the illustration for the position of the corrugated tube slit. A = binder B = outside edge of binder C = end of corrugated tube D = position of corrugated tube's slit
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L1=Max.25mm L2=Max.10mm L3=325+-10mm L4=(20mm) L5=(30mm) a=45deg

0000001901 HARNESS & CONNECTOR

Harness fixing specification (1)At the clip position J at dimension L2 from the rear end of the connector, and the dimension L1 from the metal end of the clip B, fix using the socket head bolt and the spring washer. (2)Adjust the length of dimension L1 within the tolerance so that the TPS and Np harness at A is not excessively loose, then fix using the clip. (3)Clip the GE cable and the FCV harness using clip E, the GE cable and the FCV-TCV harness using clip F, and the TPS-NP harness using clip G. B = clip D = socket head bolt E = binder F = binder G=Binder J = clip position
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L1=300+-10mm L2=(110mm) L3=27~37mm L4=5~15mm T1=9.8~13.7N-m(1.0~1.4kgf-m)

0000002001 HARNESS & CONNECTOR

Vinyl tape assembly specification Wrap with black vinyl tape (at 3 positions) from the end of the clip's metal portion at the positions shown in the figure (dimensions indicated).
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L1=55+-10mm L2=125+-10mm L3=195+-10mm L4=(20mm)

0000002101 HARNESS & CONNECTOR

Marking application specification (1)Ensure the corrugated tube is not twisted and then mark the position A shown in the figure. (2)3) Mark at the two locations indicated in the figure ( viewed from the side of the pump and the top of the pump). The markings must be the dimensions shown and approx. 5 mm wide. (3)2) Use indelible paint for steel. A = white marking B = End of tape binding
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L1=20+-5mm

Information:

Table 2
Specifications for Valve Opening Pressure
Nozzle Assembly Valve Opening Pressure
1W-5829
10300 to 17690 kPa (1500 to 2505 psi)
4W-1819
4W-8483
7E-3969
7N-0449
7W-3710
7W-8043
9N-3979
101-0060
115-3354
122-9007
9L-7883
16560 to 17990 kPa (2400 to 2600 psi)
9L-9263
9N-2366
9L-6969
13090 to 19900 kPa (1900 2900 psi)
9N-3299
9N-3700 If the fuel nozzle is not within specifications, stop the test and do not use the nozzle.Check for Tip Leakage
Close the gauge protector valve (0 to 40,000 kPa (0 to 5,800 psi) gauge).
Flush the fuel nozzle that is being tested by pumping the tester for 3 full strokes.
Open the gauge protector valve (0 to 40,000 kPa (0 to 5,800 psi) gauge).
Use a clean cloth to dry the tip and the body of the fuel injector. All test fluid should be wiped from the nozzle assembly.
A clean cloth should be wrapped around the top of the fuel nozzle in order to absorb any internal return leakage.
Calculate the test pressure that will be used for the tip leakage test.Use the fuel nozzle's valve opening pressure, that has been previously recorded, in order to calculate the test pressure for the nozzle that is being tested.
Subtract a value of 1875 kPa (275 psi) from the valve opening pressure that was previously obtained.
Record the result of the calculation as the test pressure that will be used for the tip leakage test.
Slowly apply the test pressure, that has been calculated in Step 6, to the fuel nozzle.
Close the pump isolator valve.
Hold this test pressure for 10 seconds.
Count the number of drops of test fluid that drips from the nozzle during the duration of the test. Open the pump isolator valve in order to release the pressure on the fuel nozzle when the test is completed.Refer to the information that is provided in Table 3 in order to evaluate the results of the test.Note: Ensure that any test fluid that collects on the tip of the fuel nozzle is not fluid leakage from the test fixture.
Table 3
Specifications for Tip Leakage
(Leakage within 15 seconds after the test pressure is applied to the nozzle.)
Nozzle Assembly Maximum Leakage
1W-5829 20 drops (1)
4W-1819
4W-8483
7E-3969
7N-0449
7W-3710
7W-8043
9N-3979
101-0060
115-3354
122-9007
9L-7883 3 drops (1)
9L-9263
9N-2366
9L-6969 30 drops (1)
9N-3299
9N-3700
( 1 ) No minimum specificationIf the tip leakage for the fuel nozzle is not within specifications, stop the test and do not use the fuel nozzle.Test the Fuel Nozzle for Plugged Orifices
Illustration 2 g00923165
Spray patterns for pencil type fuel nozzles.
Close the gauge protector valve (0 to 40,000 kPa (0 to 5,800 psi) gauge).
Rapidly increase the pressure on the fuel nozzle until fluid sprays from the tip of the fuel nozzle.Note: For this test, each full

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INJECTION-PUMP ASSEMBLY
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