104741-1441 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047411441 8944336251

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104741-1441 1047411441

ISUZU 8944336251 8944336251

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Cross reference number

ZEXEL 104741-1441 1047411441

ISUZU 8944336251 8944336251

Zexel num

Bosch num

Firm num

Name

104741-1441
104741-1443

8944336251 ISUZU

INJECTION-PUMP ASSEMBLY
4JD1 *

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113orSAEJ967d

Test oil temperature degC 45 45 50

Nozzle 105000-2010

Bosch type code NP-DN12SD12TT

Nozzle holder 105780-2080

Opening pressure MPa 14.7 14.7 15.19

Opening pressure kgf/cm2 150 150 155

Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-840

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)
Left L

Injection timing adjustment

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 36.2 35.7 36.7

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 36.3 32.8 39.8

Oil temperature degC 50 48 52

Injection timing adjustment_03

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 38.1 35.1 41.1

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 36.2 35.2 37.2

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 33.8 31.3 36.3

Difference in delivery mm3/st. 4.5

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 1420 1420 1420

Average injection quantity mm3/st. 13.8 10.8 16.8

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 50 48 52

Injection quantity adjustment_02

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 6

Oil temperature degC 50 48 52

Injection quantity adjustment_03

Pump speed r/min 1420 1420 1420

Average injection quantity mm3/st. 13.8 10.8 16.8

Difference in delivery mm3/st. 4.5

Oil temperature degC 50 48 52

Governor adjustment

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 9.3 7.3 11.3

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 9.3 7.3 11.3

Difference in delivery mm3/st. 2

Oil temperature degC 48 46 50

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 70 60 80

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 70 60 80

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 48 46 50

Remarks
Magnet OFF at idling position

0000000901

Pump speed r/min 800 800 800

Overflow quantity cm3/min 300 170 430

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 800 800 800

Pressure kPa 265 245 285

Pressure kgf/cm2 2.7 2.5 2.9

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 600 600 600

Pressure kPa 196 167 225

Pressure kgf/cm2 2 1.7 2.3

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 800 800 800

Pressure kPa 265 245 285

Pressure kgf/cm2 2.7 2.5 2.9

Basic *

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 1200 1200 1200

Pressure kPa 412 383 441

Pressure kgf/cm2 4.2 3.9 4.5

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 800 800 800

Timer stroke mm 1.8 1.6 2

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 600 600 600

Timer stroke mm 0.5 0.1 0.9

Oil temperature degC 50 48 52

_03

Pump speed r/min 800 800 800

Timer stroke mm 1.8 1.6 2

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 1200 1200 1200

Timer stroke mm 4.4 4.1 4.8

Oil temperature degC 50 48 52

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

Timing setting

K dimension mm 2.8 2.7 2.9

KF dimension mm 5 4.9 5.1

MS dimension mm 1.9 1.8 2

Pre-stroke mm 0.45 0.43 0.47

Control lever angle alpha deg. 20 16 24

Control lever angle beta deg. 37 32 42

Information:

Determine the fuel rail pressure and the injector test engine speed (where the peak pressure was selected). Typically, pressure will start building after 2 to 5 seconds and then there should be sampling for 5 more seconds. Illustration 7 shows an example of selecting the peak pressure and corresponding speed.
Calculate the speed change of the injector test as follows:Injector test speed change equals injector test engine speed minus pump test engine speed.
Determine injector pressure correction using the injector test speed change and Table 5. This will correct for pressure change as speed changes.
Table 5
Injector Pressure Correction Based on Speed Change
Engine speed change (rpm) 0-5 6-10 11-15 16-20 21-25 26-30 31-35
Six-cylinder pressure correction 283 kPa (41 psi) 896 kPa (130 psi) 1455 kPa (211 psi) 2013 kPa (292 psi) 2572 kPa (373 psi) 3130 kPa (454 psi) 3689 kPa (535 psi)
Four-cylinder pressure correction 159 kPa (23 psi) 510 kPa (74 psi) 834 kPa (121 psi) 1151 kPa (167 psi) 1469 kPa (213 psi) 1793 kPa (260 psi) 2110 kPa (306 psi)
If the injector test engine speed is lower than pump test engine speed, then correct the injector pressure by adding the correction as follows:Injector corrected pressure equals injector test pressure plus injector pressure correction.
If the injector test engine speed is higher than pump test engine speed (as can happen when a battery booster is used), then correct the injector test pressure by subtracting the pressure correction as follows:Injector corrected pressure equals injector test pressure minus injector pressure correction.
Calculate injector leakage ratio as follows:Injector leakage ratio equals injector corrected pressure divided by pump test rail pressure.If the Injector leakage ratio is less than 0.85, the injector must be replaced, if the injector leakage is greater than 0.85 the injector is within the required parameters.Remove the fuel line. Replace the cap on the fuel manifold (rail) and injector.
Proceed to the next injector to be checked. Repeat Step 1 through Step 8 for the remaining electronic unit injectors to be tested.
Remove components of 362-9754 Test Kit from the engine. Replace any fuel injection lines that were removed during the procedures. Refer to Disassembly and Assembly, Fuel Injection Lines - Install for the correct procedure.
Reconnect the electronic unit injector harness connectors.Test Kit Data Sheet
Table 6
Fuel Injection Pump Tests Pump Test Rail Pressure Pump Test Engine Speed Minimum Cranking Pressure (MCP) Service
From Pump Test Datalog From Pump