Information injection-pump assembly
ZEXEL
104749-6880
1047496880
Rating:
Cross reference number
ZEXEL
104749-6880
1047496880
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
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
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)
Right R
Right R
Injection timing adjustment
Pump speed
r/min
1000
1000
1000
Boost pressure
kPa
42.7
41.4
44
Boost pressure
mmHg
320
310
330
Average injection quantity
mm3/st.
39.4
38.9
39.9
Difference in delivery
mm3/st.
3.5
Basic
*
Oil temperature
degC
50
48
52
Remarks
CBS
CBS
Injection timing adjustment_02
Pump speed
r/min
1250
1250
1250
Boost pressure
kPa
69.3
68
70.6
Boost pressure
mmHg
520
510
530
Average injection quantity
mm3/st.
43.2
42.7
43.7
Difference in delivery
mm3/st.
3.5
Basic
*
Oil temperature
degC
50
48
52
Remarks
Full
Full
Injection timing adjustment_03
Pump speed
r/min
600
600
600
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
31.9
29.9
33.9
Oil temperature
degC
50
48
52
Injection timing adjustment_04
Pump speed
r/min
1000
1000
1000
Boost pressure
kPa
42.7
41.4
44
Boost pressure
mmHg
320
310
330
Average injection quantity
mm3/st.
39.4
38.4
40.4
Difference in delivery
mm3/st.
3.5
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_05
Pump speed
r/min
1250
1250
1250
Boost pressure
kPa
69.3
68
70.6
Boost pressure
mmHg
520
510
530
Average injection quantity
mm3/st.
43.2
42.2
44.2
Difference in delivery
mm3/st.
3.5
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_06
Pump speed
r/min
1250
1250
1250
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
31.4
29.4
33.4
Oil temperature
degC
50
48
52
Injection timing adjustment_07
Pump speed
r/min
2000
2000
2000
Boost pressure
kPa
69.3
68
70.6
Boost pressure
mmHg
520
510
530
Average injection quantity
mm3/st.
36.9
35.4
38.4
Oil temperature
degC
50
48
52
Injection timing adjustment_08
Pump speed
r/min
2250
2250
2250
Boost pressure
kPa
69.3
68
70.6
Boost pressure
mmHg
520
510
530
Average injection quantity
mm3/st.
35.7
34.2
37.2
Difference in delivery
mm3/st.
4.5
Oil temperature
degC
52
50
54
Injection timing adjustment_09
Pump speed
r/min
2500
2500
2500
Boost pressure
kPa
69.3
68
70.6
Boost pressure
mmHg
520
510
530
Average injection quantity
mm3/st.
34.3
32.7
35.9
Oil temperature
degC
55
52
58
Injection quantity adjustment
Pump speed
r/min
2800
2650
2950
Boost pressure
kPa
69.3
68
70.6
Boost pressure
mmHg
520
510
530
Average injection quantity
mm3/st.
18
17
19
Difference in delivery
mm3/st.
5.5
Basic
*
Oil temperature
degC
55
52
58
Injection quantity adjustment_02
Pump speed
r/min
2800
2650
2950
Boost pressure
kPa
69.3
68
70.6
Boost pressure
mmHg
520
510
530
Average injection quantity
mm3/st.
18
17
19
Difference in delivery
mm3/st.
5.5
Oil temperature
degC
55
52
58
Governor adjustment
Pump speed
r/min
425
425
425
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
8
6
10
Difference in delivery
mm3/st.
2
Basic
*
Oil temperature
degC
48
46
50
Governor adjustment_02
Pump speed
r/min
425
425
425
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
8
6
10
Difference in delivery
mm3/st.
2
Oil temperature
degC
48
46
50
Timer adjustment
Pump speed
r/min
100
100
100
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
70
40
100
Basic
*
Oil temperature
degC
48
46
50
Remarks
Full
Full
Timer adjustment_02
Pump speed
r/min
100
100
100
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
40
40
Oil temperature
degC
48
46
50
Speed control lever angle
Pump speed
r/min
425
425
425
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
0
0
0
Oil temperature
degC
48
46
50
Remarks
Magnet OFF at idling position
Magnet OFF at idling position
0000000901
Pump speed
r/min
1250
1250
1250
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Overflow quantity
cm3/min
460
330
590
Oil temperature
degC
50
48
52
Stop lever angle
Pump speed
r/min
2000
2000
2000
Boost pressure
kPa
69.3
68
70.6
Boost pressure
mmHg
520
510
530
Pressure
kPa
628
608
648
Pressure
kgf/cm2
6.4
6.2
6.6
Basic
*
Oil temperature
degC
50
48
52
Stop lever angle_02
Pump speed
r/min
1250
1250
1250
Boost pressure
kPa
69.3
68
70.6
Boost pressure
mmHg
520
510
530
Pressure
kPa
431
402
460
Pressure
kgf/cm2
4.4
4.1
4.7
Oil temperature
degC
50
48
52
Stop lever angle_03
Pump speed
r/min
2000
2000
2000
Boost pressure
kPa
69.3
68
70.6
Boost pressure
mmHg
520
510
530
Pressure
kPa
628
608
648
Pressure
kgf/cm2
6.4
6.2
6.6
Basic
*
Oil temperature
degC
50
48
52
Stop lever angle_04
Pump speed
r/min
2175
2175
2175
Boost pressure
kPa
69.3
68
70.6
Boost pressure
mmHg
520
510
530
Pressure
kPa
677
648
706
Pressure
kgf/cm2
6.9
6.6
7.2
Oil temperature
degC
52
50
54
0000001101
Pump speed
r/min
2000
2000
2000
Boost pressure
kPa
69.3
68
70.6
Boost pressure
mmHg
520
510
530
Timer stroke
mm
6.9
6.7
7.1
Basic
*
Oil temperature
degC
50
48
52
_02
Pump speed
r/min
720
620
820
Boost pressure
kPa
69.3
68
70.6
Boost pressure
mmHg
520
510
530
Timer stroke
mm
0.5
0.5
0.5
Oil temperature
degC
50
48
52
_03
Pump speed
r/min
1250
1250
1250
Boost pressure
kPa
69.3
68
70.6
Boost pressure
mmHg
520
510
530
Timer stroke
mm
3.2
2.8
3.6
Oil temperature
degC
50
48
52
_04
Pump speed
r/min
2000
2000
2000
Boost pressure
kPa
69.3
68
70.6
Boost pressure
mmHg
520
510
530
Timer stroke
mm
6.9
6.7
7.1
Basic
*
Oil temperature
degC
50
48
52
_05
Pump speed
r/min
2175
2175
2175
Boost pressure
kPa
69.3
68
70.6
Boost pressure
mmHg
520
510
530
Timer stroke
mm
7.8
7.5
8.2
Oil temperature
degC
52
50
54
0000001201
Max. applied voltage
V
8
8
8
Test voltage
V
13
12
14
0000001401
Pump speed
r/min
2000
2000
2000
Boost pressure
kPa
69.3
68
70.6
Boost pressure
mmHg
520
510
530
Average injection quantity
mm3/st.
29
28.5
29.5
Timer stroke TA
mm
5.9
5.9
5.9
Timer stroke variation dT
mm
1
0.8
1.2
Basic
*
Oil temperature
degC
50
48
52
_02
Pump speed
r/min
2000
2000
2000
Boost pressure
kPa
69.3
68
70.6
Boost pressure
mmHg
520
510
530
Average injection quantity
mm3/st.
29
28
30
Timer stroke variation dT
mm
1
0.6
1.4
Basic
*
Oil temperature
degC
50
48
52
_03
Pump speed
r/min
2000
2000
2000
Boost pressure
kPa
69.3
68
70.6
Boost pressure
mmHg
520
510
530
Average injection quantity
mm3/st.
20
19
21
Timer stroke variation dT
mm
2
1.4
2.6
Oil temperature
degC
50
48
52
Timing setting
K dimension
mm
3.3
3.2
3.4
KF dimension
mm
5.8
5.7
5.9
MS dimension
mm
1.6
1.5
1.7
BCS stroke
mm
4
3.8
4.2
Control lever angle alpha
deg.
20
16
24
Control lever angle beta
deg.
40
39
41
Test data Ex:
0000001801 V-FICD ADJUSTMENT
Adjustment of the V-FICD (perform with W-FICD released)
1. Adjust to obtain L1.
2. Set at L2 when negative pressure P1 is applied to the actuator.
Adjust the stroke using the actuator stroke adjusting screw (F).
(A) Pin
(B) Actuator shaft
(C) Control lever
(D) Actuator
(E) Lock nut (Torque T)
----------
L1=1+1mm L2=0.84+-0.1mm P1=-46.7kPa(-350mmHg) T=1.2~1.5N-m(0.12~0.15kgf-m)
----------
L1=1+1mm L2=0.84+-0.1mm T=1.2~1.5N-m(0.12~0.15kgf-m)
----------
L1=1+1mm L2=0.84+-0.1mm P1=-46.7kPa(-350mmHg) T=1.2~1.5N-m(0.12~0.15kgf-m)
----------
L1=1+1mm L2=0.84+-0.1mm T=1.2~1.5N-m(0.12~0.15kgf-m)
0000001901 W-CSD ADJUSTMENT
Adjustment of the W-CSD
1. Adjustment of the timer stroke
Adjust using the screw (A) so that the timer stroke is the same as the value determined from the graph (M).
(M) Timer stroke (mm), (1) TA = -0.0235t+1.17
Lever position (deg) (2) theta = -0.0625t+4.85 (-20 <= t <= 20 (deg C))
Theta 2 = -0.12t + 6 (20 deg C =< t =< 50 deg C)
Lever position (mm) (3) L1 = -0.02075t+1.585 (-20 <= t <= 20 (deg C))
L2 = -0.039t + 1.95 (20 deg C =< t =< 50 deg C)
(3 shows the gap between the control lever and the idle set screw.)
2. Adjustment of the position of the intermediate lever.
Insert a shim L1 between the control lever (I) and the idle set screw (G).
Align the intermediate lever (F) with the aligning line (J) and fix screw (E) so that it contacts the control lever.
3. Adjustment of the FICD
Insert a shim L2 between the control lever (I) and the idle set screw (G).
Use adjusting screw (B) to fix the CSD lever (C) in the position where it operates the intermediate lever via the rod (D).
X:Temperature (deg C)
Y1:Timer stroke (mm)
Y2:Control lever position (deg)
(S) Cold advancer cooling water temperature increase direction
K:Standard point
N:Pump speed
(R) Cooling water temperature
(O) Timer piston stroke
(P) Lever position
(Q) lever position
----------
L1=1.2+-0.05mm L2=L1+-0.05mm
----------
L1=1.2+-0.05mm N1=500r/min a=20degC b=-20degC c=3.6+-1deg d=6.1+-3deg O1=0.7+-0.2mm O2=1.6+-0.4mm Q1=1.2+-0.3mm Q2=2+-1mm
----------
L1=1.2+-0.05mm L2=L1+-0.05mm
----------
L1=1.2+-0.05mm N1=500r/min a=20degC b=-20degC c=3.6+-1deg d=6.1+-3deg O1=0.7+-0.2mm O2=1.6+-0.4mm Q1=1.2+-0.3mm Q2=2+-1mm
Information:
Flywheel
Installation of Flywheel Housing
Installation of flywheel housing(1) Install the oil seal to the flywheel housing.(2) Coat the contact surfaces of the crankcase and flywheel with ThreeBond 1104.(3) Align the holes in the flywheel housing and gasket with the dowel pins on the crankcase, and install them to the crankcase.Installation of Flywheel
(1) Install the flywheel to the crankshaft by aligning the hole with the dowel pin on the back-end of the crankshaft.(2) Place the washer and tighten the four bolts to the specified torque.
Installation of flywheelMeasurement of Flywheel Runout
Measure the flywheel runout with the flywheel installed to the crankshaft. If the standard value is exceeded, check the bolts for tightening condition and the mounting face for adhesion of foreign particles.
Measurement of face runout and circular runoutCylinder Head and Valve Mechanisms
Installation of Valve Stem Seal
(1) Apply engine oil to the valve stem, and insert it into the valve guide.(2) Place a new stem seal on the valve guide.(3) Using the stem seal installer, install the stem seal to the valve guide, making use of the valve stem as a guide.
Installation of valve stem sealInstallation of Valves and Valve Springs
(1) Place the valve spring and retainer on the valve guide, and install the valve cotter using the valve spring pusher.
Excessive compression of the valve spring can cause the retainer to contact the stem seal and damage the seal.
Installation of valve and valve spring(2) Using a soft-faced hammer, tap the top of the valve stem several times to make sure that the spring and valve cotter are securely installed.
Confirmation of secure valve cotter installationInstallation of Cylinder Head Gasket
(1) Make sure that the top face of the crankcase and piston upper surfaces are clean and free of dust.(2) Place a new gasket of the crankcase, making sure that the dowel pins on the top face of the crankcase enter the holes in the gasket.
Do not use a liquid gasket.
Installation of cylinder head gasketInstallation of Cylinder Head
Place the cylinder head on the head gasket, making sure that the dowel pins on the top face of the crankcase enters the holes in the cylinder head.
Installation of cylinder head assemblyTightening of Cylinder Head Bolts
Tighten the cylinder head bolts, following the tightening sequence shown in the diagram two or three times before reaching the specified torque.
Cylinder head bolt tightening sequenceAssembly of Rocker Arm and Rocker Shaft Assembly
When installing the rocker arms, make sure that the shaft assembly marks face the front of the engine, as shown in the diagram. After the assembly, make sure that the rocker arms move smoothly.
Assembly of rocker shaft assemblyInstallation of Pushrods
(1) Insert the pushrods in the cylinder head through the pushrod holes.(2) Make sure that the ball end of each pushrod rests securely on the curved surface of the tappet.Installation of Rocker Shaft Assemblies
(1) Install the valve caps.(2) When installing the rocker shaft brackets, tighten the long bolts first, then tighten the short bolts (reversal of removal sequence).
Installation of rocker shaft assemblyAdjustment of Valve Clearances
(1) Confirming the top dead center on the
Installation of Flywheel Housing
Installation of flywheel housing(1) Install the oil seal to the flywheel housing.(2) Coat the contact surfaces of the crankcase and flywheel with ThreeBond 1104.(3) Align the holes in the flywheel housing and gasket with the dowel pins on the crankcase, and install them to the crankcase.Installation of Flywheel
(1) Install the flywheel to the crankshaft by aligning the hole with the dowel pin on the back-end of the crankshaft.(2) Place the washer and tighten the four bolts to the specified torque.
Installation of flywheelMeasurement of Flywheel Runout
Measure the flywheel runout with the flywheel installed to the crankshaft. If the standard value is exceeded, check the bolts for tightening condition and the mounting face for adhesion of foreign particles.
Measurement of face runout and circular runoutCylinder Head and Valve Mechanisms
Installation of Valve Stem Seal
(1) Apply engine oil to the valve stem, and insert it into the valve guide.(2) Place a new stem seal on the valve guide.(3) Using the stem seal installer, install the stem seal to the valve guide, making use of the valve stem as a guide.
Installation of valve stem sealInstallation of Valves and Valve Springs
(1) Place the valve spring and retainer on the valve guide, and install the valve cotter using the valve spring pusher.
Excessive compression of the valve spring can cause the retainer to contact the stem seal and damage the seal.
Installation of valve and valve spring(2) Using a soft-faced hammer, tap the top of the valve stem several times to make sure that the spring and valve cotter are securely installed.
Confirmation of secure valve cotter installationInstallation of Cylinder Head Gasket
(1) Make sure that the top face of the crankcase and piston upper surfaces are clean and free of dust.(2) Place a new gasket of the crankcase, making sure that the dowel pins on the top face of the crankcase enter the holes in the gasket.
Do not use a liquid gasket.
Installation of cylinder head gasketInstallation of Cylinder Head
Place the cylinder head on the head gasket, making sure that the dowel pins on the top face of the crankcase enters the holes in the cylinder head.
Installation of cylinder head assemblyTightening of Cylinder Head Bolts
Tighten the cylinder head bolts, following the tightening sequence shown in the diagram two or three times before reaching the specified torque.
Cylinder head bolt tightening sequenceAssembly of Rocker Arm and Rocker Shaft Assembly
When installing the rocker arms, make sure that the shaft assembly marks face the front of the engine, as shown in the diagram. After the assembly, make sure that the rocker arms move smoothly.
Assembly of rocker shaft assemblyInstallation of Pushrods
(1) Insert the pushrods in the cylinder head through the pushrod holes.(2) Make sure that the ball end of each pushrod rests securely on the curved surface of the tappet.Installation of Rocker Shaft Assemblies
(1) Install the valve caps.(2) When installing the rocker shaft brackets, tighten the long bolts first, then tighten the short bolts (reversal of removal sequence).
Installation of rocker shaft assemblyAdjustment of Valve Clearances
(1) Confirming the top dead center on the