106671-0141 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066710141

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106671-0141 1066710141

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Cross reference number

ZEXEL 106671-0141 1066710141

Zexel num

Bosch num

Firm num

Name

106671-0141

INJECTION-PUMP ASSEMBLY

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 8-3-600

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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 1-4-2-6- 3-5

Pre-stroke mm 3.65 3.6 3.7

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position R2(11.7)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 158.6 154.6 162.6

Max. variation between cylinders % 0 -5 5

Fixing the lever *

Boost pressure kPa 29.3 29.3

Boost pressure mmHg 220 220

Injection quantity adjustment_02

Adjusting point B

Rack position 12.1

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 170.1 168.1 172.1

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Boost pressure kPa 29.3 29.3

Boost pressure mmHg 220 220

Injection quantity adjustment_03

Adjusting point C

Rack position 7.4+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 10.1 9.1 11.1

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_04

Adjusting point D

Rack position R1(10.9)

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 126.5 124.5 128.5

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_05

Adjusting point E

Rack position 12.3

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 171.1 166.1 176.1

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 300 300 300

Rack position R1(10.9)

Boost pressure kPa 4

Boost pressure mmHg 30

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position 12.3

Boost pressure kPa 16 16 16

Boost pressure mmHg 120 120 120

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Damper spring setting: DL (2)Rack limit using stop lever
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DL=6.4-0.2mm
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Timer adjustment

(1)Adjusting range (2)Step response time (N): Speed of the pump (L): Load (theta) Advance angle (Srd1) Step response time 1 (Srd2) Step response time 2 1. Adjusting conditions for the variable timer (1)Adjust the clearance between the pickup and the protrusion to L.
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L=1-0.2mm N2=800r/min C2=(6.5)deg t1=2--sec. t2=2--sec.
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N1=1250++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=6.5+-0.5deg R01=0/4load R02=4/4load

Speed control lever angle

F:Full speed
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a=30deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)At center of threaded hole above R = aa
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aa=17mm
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a=22deg+-5deg b=33deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb (3)R = cc (4)Adjust after setting excess fuel lever.
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aa=1+0.5mm bb=12.3mm cc=50mm
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a=32.5deg+-5deg b=19.5deg+-5deg

0000001101

N:Normal B:When boosted (1)Rack position = aa
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aa=13mm
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a=(18deg) b=(32deg)

0000001501 RACK SENSOR

V1:Supply voltage V2f:Full side output voltage V2i:Idle side output voltage (A) Black (B) Yellow (C) Red (D) Trimmer (E): Shaft (F) Nut (G) Load lever 1. Load sensor adjustment (1)Connect as shown in the above diagram and apply supply voltage V1. (2)Hold the load lever (G) against the full side. (3)Turn the shaft so that the voltage between (A) and (B) is V2. (4)Hold the load lever (G) against the idle side. (5)Adjust (D) so that the voltage between (A) and (B) is V2i. (6)Repeat the above adjustments. (7)Tighten the nut (F) at the point satisfying the standards. (8)Hold the load lever against the full side stopper and the idle side stopper. (9)At this time, confirm that the full side output voltage is V2f and the idle side output voltage is V2i.
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V1= 5+-0.02V V2f=0.3+0.03V V2i=2.2-0.03V
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Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

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a=(20deg)

Information:

(1) Nut (4K0367)(2) Bearing (9U6877)(3) Washer (5P8247)(4) Bridge plate (9U7259)(5) Bolts (5/16)(6) Threaded rod puller stud (221-9778)(7) Threaded end
Install the remaining parts of Tool B on the threadedrod assembly (item 6).
Lubricate the threads on (item 6).
Tighten nut (item 1) in order to remove the unitinjector sleeve. Do not use an impact wrench.
After the sleeve is removed, use the large 4C5552wire brush to remove dirt and sealant from the bore. Squirt isopropyl alcoholor brake cleaner into the bore to remove oil. Use paper towels and swabsto remove all debris from the bore. Ensure the injector bore and fuel railare clean and free from debris.
Any sealant, fuel, oil or debris willprevent the sealant from properly curing. Improper cleaning will lead toa poor sealing surface and leak path.
Table 3 Unit Injector Sleeve ? InstallRequired Tools
ToolA
Part Number Description Quantity
2219777 Sleeve Installer 1
4C9507 Locktite 620 Sealant 1 Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure the o-ring (8T7878) is in place on the2219777 sleeve installer
Place the 1785037 unit injector sleeve on ToolA.
Clean the sleeve with isopropyl alcohol and wipedry with as clean paper towel. Note: Make sure the sleeve is free ofall debris, oil and fuel.
Apply 4C9507 Locktite 620 sealant (shake wellbefore using, sealant can separate) to the upper land and lower land ofthe unit injector sleeve.
Surfaces to be sealed must be freeof oil, grease, fuel, etc.
Install the unit injector sleeve into the injectorsleeve bore.
Use a hammer to drive the sleeve into the headuntil the sleeve bottoms out.
Wipe all excess anaerobic from the injector borewith a paper towel and swab.
Stamp AH on the front left top of the cylinderhead near the HEP 8 pump to verify the rework has been completed.
Wait approximately two (2) hours atroom temperature (70F) before filling the engine with fuel or coolant.Longer curing time is needed at lower temperatures.Unit injectors ? Installation procedure
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Part Number Description Quantity
Tool A 1492955 Seal Protector 1
Tool B 1492956 Seal Installer 1
Install injection actuation pressure sensor. Torquethe sensor to 10 2 N m (88 18 lb in).
Install the fuel lines and fittings as needed.Torque to specifications.
Lubricate the O-Ring seals and the sleeve boreof the injector sparingly with clean engine oil.
Install injector in the cylinder head. Positionthe injector into the cylinder head. Use your hand to install the injectorinto the cylinder head. Install socket head bolt on the exhaust side ofthe hold down bracket. Tighten the exhaust side of socket head bolt untilthe bolt is seated. Install and tighten the inlet side of socket head boltto a torque of 12 1 N m (9 1 lb ft).
Install the valve mechanism cover. Refer to Disassemblyand Assembly, "Valve Mechanism Cover - Remove and Install".
If the o-rings are damaged and needreplaced.
Use Tool (A) and Tool (B) to install the upper high-pressure seal pack.
Install the upper seal pack first. Then installthe middle seal pack. Finally, install the bottom O-Ring Seal.
Install Tool (A) on the injector.
Use Tool (B) to install backup rings and O-ringseal on the unit injector. Lubricate the O-ring seals and