Information injection-pump assembly
BOSCH
9 460 613 549
9460613549
ZEXEL
104701-1002
1047011002
ISUZU
8971242461
8971242461

Rating:
Components :
0. | INJECTION-PUMP ASSEMBLY | 104701-1002 |
1. | _ | |
2. | FUEL INJECTION PUMP | 104601-1002 |
3. | NUMBER PLATE | 146966-4500 |
4. | _ | |
5. | CAPSULE | |
6. | ADJUSTING DEVICE | |
7. | NOZZLE AND HOLDER ASSY | 105158-2264 |
8. | Nozzle and Holder | 8-97021-474-2 |
9. | Open Pre:MPa(Kqf/cm2) | 14.7{150} |
10. | NOZZLE-HOLDER | 105088-1120 |
11. | NOZZLE | 105007-1240 |
Scheme ###:
1/6. | [1] | 146601-0100 | 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 |
12/3. | [1] | 146201-0000 | WOODRUFF KEY |
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] | 146220-4420 | CAM PLATE |
30. | [1] | 146600-3000 | O-RING |
31. | [1] | 146300-1900 | PUMP PLUNGER |
32. | [1] | 146301-0200 | SLIDING PIECE |
33/1. | [0] | 146603-0700 | SHIM D17.5&7.5T0.60 |
33/1. | [0] | 146603-0800 | SHIM D17.5&7.5T0.70 |
33/1. | [0] | 146603-0900 | SHIM D17.5&7.5T0.90 |
33/1. | [0] | 146603-1000 | SHIM D17.5&7.5T1.00 |
33/1. | [0] | 146603-1100 | SHIM D17.5&7.5T1.20 |
33/1. | [0] | 146603-3600 | SHIM D17.5&7.5T2.40 |
34. | [1] | 146306-1800 | 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] | 146600-3000 | O-RING |
37. | [1] | 479773-4320 | 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] | 146234-0120 | GUIDE PIN |
50. | [1] | 146403-6620 | HYDRAULIC HEAD |
50. | [1] | 146403-6620 | HYDRAULIC HEAD |
50. | [1] | 146403-6620 | 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 D12&6.4T1.00 |
55. | [4] | 146430-0320 | DELIVERY-VALVE ASSEMBLY |
56. | [4] | 146432-0700 | COMPRESSION SPRING |
58. | [4] | 146440-0120 | FITTING |
60. | [3] | 139106-0100 | FLAT-HEAD SCREW |
123. | [1] | 146620-8800 | FLAT-HEAD SCREW |
130. | [1] | 146421-0420 | CAPSULE |
130/2. | [1] | 139508-0200 | GASKET D11.4&8.2T1 |
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] | 146110-1120 | CONTROL VALVE |
135/5. | [1] | 146114-0000 | SPRING WASHER |
136. | [1] | 148120-0020 | OVER FLOW VALVE |
137. | [3] | 139512-0500 | GASKET |
138. | [1] | 148610-0620 | INLET UNION |
158. | [1] | 146614-6900 | SPACER BUSHING |
200. | [1] | 146206-0100 | COILED SPRING |
205. | [1] | 029470-4030 | WOODRUFF KEY |
230. | [1] | 148613-0820 | 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] | 139812-0500 | EYE BOLT |
247. | [1] | 146605-6120 | INLET UNION |
248. | [1] | 146614-0200 | SPACER BUSHING |
275. | [1] | 148612-0520 | BRACKET |
276. | [2] | 010210-1640 | HEX-SOCKET-HEAD CAP SCREW |
282. | [1] | 139006-4400 | BLEEDER SCREW |
504/1. | [1] | 146649-4500 | RESISTER |
504/1. | [1] | 146649-4600 | RESISTER |
504/1. | [1] | 146649-4700 | RESISTER |
504/1. | [1] | 146649-4800 | RESISTER |
504/1. | [1] | 146649-4900 | RESISTER |
504/1. | [1] | 146649-5000 | RESISTER |
504/1. | [1] | 146649-5100 | RESISTER |
504/1. | [1] | 146649-5200 | RESISTER |
504/1. | [1] | 146649-5300 | RESISTER |
504/1. | [1] | 146649-5400 | RESISTER |
504/1. | [1] | 146649-5500 | RESISTER |
504/1. | [1] | 146649-5600 | RESISTER |
504/1. | [1] | 146649-5700 | RESISTER |
505. | [1] | 148530-0421 | GOVERNOR;ELECTRIC |
506. | [3] | 146620-8900 | FLAT-HEAD SCREW |
509. | [1] | 148600-1300 | SEAL RING |
515. | [1] | 106144-1051 | TIMING CONTROL VALVE |
515/12. | [1] | 161440-3800 | O-RING |
515/13. | [1] | 161440-3700 | O-RING |
516. | [2] | 010206-1440 | HEX-SOCKET-HEAD CAP SCREW M6P1L14 |
531. | [1] | 479773-7220 | PULSE GENERATOR |
531/6. | [1] | 479773-6500 | O-RING |
800S. | [1] | 148009-0220 | PUMP HOUSING |
800S/1/6. | [1] | 146601-0700 | PACKING RING |
804S. | [1] | 146232-0720 | COMPRESSION SPRING |
906. | [1] | 146966-4500 | NAMEPLATE |
Include in #2:
104701-1002
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 460 613 549
9460613549
ZEXEL
104701-1002
1047011002
ISUZU
8971242461
8971242461
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113orSAEJ967d
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
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
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
588.5
559
618
Pump chamber pressure
kgf/cm2
6
5.7
6.3
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
588
549
627
Pump chamber pressure
kgf/cm2
6
5.6
6.4
Governor adjustment_04
Pump speed
r/min
1800
1800
1800
TCV duty (%) F TCV 60Hz
%
100
100
100
U alpha soll
V
2.7
2.7
2.7
Pump chamber pressure
kPa
706
657
755
Pump chamber pressure
kgf/cm2
7.2
6.7
7.7
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
8.6
8.4
8.8
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
2.5
0.4
4.6
Boost compensator adjustment_03
Pump speed
r/min
500
500
500
TCV duty (%) F TCV 60Hz
%
100
100
100
U alpha soll
V
2.7
2.7
2.7
Timer stroke
mm
7.5
5.4
9.6
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
8.6
8.3
8.9
Boost compensator adjustment_05
Pump speed
r/min
1000
1000
1000
TCV duty (%) F TCV 60Hz
%
70
70
70
U alpha soll
V
2.7
2.7
2.7
Timer stroke
mm
4.5
3.4
5.6
Boost compensator adjustment_06
Pump speed
r/min
1800
1800
1800
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
2300
2300
2300
TCV duty (%) F TCV 60Hz
%
0
0
0
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
2.09
1.867
2.313
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
560
430
690
0000000901
Pump speed
r/min
1000
1000
1000
U alpha soll + dU alpha soll
V
2.86
2.86
2.86
TCV duty (%) F TCV 60Hz
%
100
100
100
Average injection quantity
mm3/st.
84.4
83.9
84.9
Difference in delivery
mm3/st.
4.5
Basic
*
_02
Pump speed
r/min
360
360
360
U alpha soll + dU alpha soll
V
1.73
1.73
1.73
TCV duty (%) F TCV 60Hz
%
100
100
100
Average injection quantity
mm3/st.
12.7
9.7
15.7
Difference in delivery
mm3/st.
2
Basic
*
Remarks
Confirmation of difference in delivery
Confirmation of difference in delivery
_03
Pump speed
r/min
1800
1800
1800
U alpha soll + dU alpha soll
V
2.93
2.93
2.93
TCV duty (%) F TCV 60Hz
%
100
100
100
Average injection quantity
mm3/st.
84.1
81.1
87.1
Difference in delivery
mm3/st.
10
Basic
*
Remarks
Confirmation of difference in delivery
Confirmation of difference in delivery
_04
Pump speed
r/min
100
100
100
U alpha soll + dU alpha soll
V
2.86
2.86
2.86
TCV duty (%) F TCV 60Hz
%
100
100
100
Average injection quantity
mm3/st.
81.8
71.8
91.8
_05
Pump speed
r/min
360
360
360
U alpha soll + dU alpha soll
V
1.73
1.73
1.73
TCV duty (%) F TCV 60Hz
%
100
100
100
Average injection quantity
mm3/st.
12.7
9.2
16.2
_06
Pump speed
r/min
500
500
500
U alpha soll + dU alpha soll
V
2.5
2.5
2.5
TCV duty (%) F TCV 60Hz
%
100
100
100
Average injection quantity
mm3/st.
65.75
62.5
69
_07
Pump speed
r/min
1000
1000
1000
U alpha soll + dU alpha soll
V
2.86
2.86
2.86
TCV duty (%) F TCV 60Hz
%
100
100
100
Average injection quantity
mm3/st.
84.4
83.4
85.4
_08
Pump speed
r/min
1800
1800
1800
U alpha soll + dU alpha soll
V
2.93
2.93
2.93
TCV duty (%) F TCV 60Hz
%
100
100
100
Average injection quantity
mm3/st.
84.1
80.6
87.6
_09
Pump speed
r/min
2300
2300
2300
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
1800
1800
1800
U alpha soll + dU alpha soll
V
2.93
2.93
2.93
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
N=Measure the actual speed. r/min N+-8
0000001201
Pump speed
r/min
1000
1000
1000
TCV duty (%) F TCV 60Hz
%
100
100
100
U alpha soll
V
2.86
2.86
2.86
Temperature output
Measure T = actual output temperature degC T+-5
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
5.8
5.7
5.9
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

Connector and binder assembly specification
(1)Assemble the connectors and clips in the order A, B, C, D, E, F and G.
(2)Run A and B's connectors under C's harness and fix.
(3)After confirming that A and B's harness is routed under C's harness at J, fix clip F.
A:P/U Connector
B:T.P.S. Connector
C:G.E. Connector
D:Q adjustment connector
E:T.C.V. Connector
F:Push type clip
G:Clip for GE.
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Information:
Introduction
The following procedures contain crucial information on correctly installing the new 162-2501 Hose As and the 258-8917 Protection Sleeve .Note: The 162-2501 Hose As replaces 107-7942 Tube As .Installation Procedure of the Hose Assembly
Illustration 1 g01230674
Remove old 162-2501 Hose As (1). Keep all of the manifold and pump fittings attached.Note: Step 2 is only for 3408E engines.
Remove the 7W-6492 Pipe Plug (2) from the aftercooler housing (3). Install the 8T-6762 Pipe Plug into the aftercooler housing.
Illustration 2 g01230678
Note: Always tighten the fittings with your hand before you use a wrench. Support the hose and the elbow while you tighten in order to avoid the following damage: twisting, kinking and side loading.
Loosen elbow (4) and jam nut (5) .
Hand tighten the nut on the hose (5) to the elbow (4) .
Install the other end of the hose (6) to the pump fitting. Tighten the nut to 125 15 N m (90 11 lb ft).
Hold the elbow (4) in position and torque the jam nut to 145 15 N m (105 11 lb ft).
Support the elbow (4). Tighten the nut (5) on the hose to 125 15 N m (90 11 lb ft).
Illustration 3 g01230687
Illustration 3 shows the routing of the 162-2501 Hose As (8). The hose is routed from the rail, around the rear of the fuel transfer pump (9), and into the 90 degree fitting (7) that is installed into the pump.
Illustration 4 g01230689
Some 3408 engines use an aftercooler that is mounted high. The mounting bracket (10) is located close to the 162-2501 Hose As (8). If there is not enough clearance to install the protective sleeve, the hose will need to be loosened and the hose will need to be repositioned. Refer to 5 for repositioning of the hose.
Illustration 5 g01230690
The hose must be realigned if any of the following conditions exist:
Not enough clearance against the fuel transfer pump
Not enough clearance against the support bracket
Loosen the end of the hose (12) .
Loosen the elbow and the jam nut (11). Note: Do not remove the hose.
Reposition the hose in order to acquire the desired clearance.
Hold the end of the hose (12). Tighten the jam nut (11) .Tighten the jam nut to the following torque. ... 143 15 N m (105 11 lb ft)Note: Locking pliers can be used on the crimped portion of the hose. Do not use the locking pliers on the braided portion of the hose. This will damage the hose which will cause a failure.
Tighten the end of the hose (12) .Tighten the end of the hose to the following torque. ... 125 15 N m (92 11 lb ft)Note: If adjustment of the hose is required, make sure that the hose is not bent. Also, ensure that the hose is not twisted. If these conditions exist the PTFE liner can be damaged.Installation of the Protective Sleeve Over the New Hose Assembly
Illustration 6 g01106118
Top viewInstallation of a protective sleeve for the hoses of the
The following procedures contain crucial information on correctly installing the new 162-2501 Hose As and the 258-8917 Protection Sleeve .Note: The 162-2501 Hose As replaces 107-7942 Tube As .Installation Procedure of the Hose Assembly
Illustration 1 g01230674
Remove old 162-2501 Hose As (1). Keep all of the manifold and pump fittings attached.Note: Step 2 is only for 3408E engines.
Remove the 7W-6492 Pipe Plug (2) from the aftercooler housing (3). Install the 8T-6762 Pipe Plug into the aftercooler housing.
Illustration 2 g01230678
Note: Always tighten the fittings with your hand before you use a wrench. Support the hose and the elbow while you tighten in order to avoid the following damage: twisting, kinking and side loading.
Loosen elbow (4) and jam nut (5) .
Hand tighten the nut on the hose (5) to the elbow (4) .
Install the other end of the hose (6) to the pump fitting. Tighten the nut to 125 15 N m (90 11 lb ft).
Hold the elbow (4) in position and torque the jam nut to 145 15 N m (105 11 lb ft).
Support the elbow (4). Tighten the nut (5) on the hose to 125 15 N m (90 11 lb ft).
Illustration 3 g01230687
Illustration 3 shows the routing of the 162-2501 Hose As (8). The hose is routed from the rail, around the rear of the fuel transfer pump (9), and into the 90 degree fitting (7) that is installed into the pump.
Illustration 4 g01230689
Some 3408 engines use an aftercooler that is mounted high. The mounting bracket (10) is located close to the 162-2501 Hose As (8). If there is not enough clearance to install the protective sleeve, the hose will need to be loosened and the hose will need to be repositioned. Refer to 5 for repositioning of the hose.
Illustration 5 g01230690
The hose must be realigned if any of the following conditions exist:
Not enough clearance against the fuel transfer pump
Not enough clearance against the support bracket
Loosen the end of the hose (12) .
Loosen the elbow and the jam nut (11). Note: Do not remove the hose.
Reposition the hose in order to acquire the desired clearance.
Hold the end of the hose (12). Tighten the jam nut (11) .Tighten the jam nut to the following torque. ... 143 15 N m (105 11 lb ft)Note: Locking pliers can be used on the crimped portion of the hose. Do not use the locking pliers on the braided portion of the hose. This will damage the hose which will cause a failure.
Tighten the end of the hose (12) .Tighten the end of the hose to the following torque. ... 125 15 N m (92 11 lb ft)Note: If adjustment of the hose is required, make sure that the hose is not bent. Also, ensure that the hose is not twisted. If these conditions exist the PTFE liner can be damaged.Installation of the Protective Sleeve Over the New Hose Assembly
Illustration 6 g01106118
Top viewInstallation of a protective sleeve for the hoses of the