Information injection-pump assembly
ZEXEL
106671-1941
1066711941
ISUZU
1156029490
1156029490
Rating:
Cross reference number
ZEXEL
106671-1941
1066711941
ISUZU
1156029490
1156029490
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
134424-1920
Overflow valve opening pressure
kPa
127
107
147
Overflow valve opening pressure
kgf/cm2
1.3
1.1
1.5
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-4-2-6-
3-5
Pre-stroke
mm
3.8
3.77
3.83
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
A
Rack position
11.5
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
192
190
194
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
32.7
32.7
Boost pressure
mmHg
245
245
Injection quantity adjustment_02
Adjusting point
C
Rack position
5.3+-0.5
Pump speed
r/min
230
230
230
Average injection quantity
mm3/st.
12.5
9.3
15.7
Max. variation between cylinders
%
0
-13
13
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
D
Rack position
11
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
183.5
177.5
189.5
Fixing the lever
*
Boost pressure
kPa
32.7
32.7
Boost pressure
mmHg
245
245
Boost compensator adjustment
Pump speed
r/min
750
750
750
Rack position
9.2
Boost pressure
kPa
6.7
6.7
8
Boost pressure
mmHg
50
50
60
Boost compensator adjustment_02
Pump speed
r/min
750
750
750
Rack position
11.5
Boost pressure
kPa
19.3
12.6
26
Boost pressure
mmHg
145
95
195
Timer adjustment
Pump speed
r/min
700--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
650
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
900
Advance angle
deg.
3
2.5
3.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Lever ratio: RT
(2)Target shim dimension: TH
(3)Tolerance for racks not indicated: +-0.05mm.
(4)Supplied with torque spring not set.
(5)Excess fuel setting for starting: SXL (N = N1)
(6)Damper spring setting
(7)Boost compensator stroke: BCL
----------
RT=1 TH=2.6mm SXL=11.8+0.2mm N1=350r/min BCL=2.3+-0.1mm
----------
----------
RT=1 TH=2.6mm SXL=11.8+0.2mm N1=350r/min BCL=2.3+-0.1mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=3.5deg+-5deg
----------
----------
a=3.5deg+-5deg
0000000901
F:Full load
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
(3)When load lever is cancelled.
----------
aa=32mm
----------
a=30deg+-5deg b=33deg+-3deg c=(8.5deg)
----------
aa=32mm
----------
a=30deg+-5deg b=33deg+-3deg c=(8.5deg)
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Drive side
----------
----------
a=32deg+-5deg b=64deg+-5deg
----------
----------
a=32deg+-5deg b=64deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of timer's threaded hole at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=15deg
----------
a=(70deg)
----------
aa=15deg
----------
a=(70deg)
Information:
Start By:a. remove oil panb. remove oil pump 1. Remove bolts (1) and bearing cap (2). Remove the bearing half from the cap.
If the crankshaft is turned in the wrong direction, the tab of the bearing will be pushed between the crankshaft and cylinder block. This can cause damage to either or both the crankshaft and the block.
2. Remove the upper half of the main bearings as follows:a. Turn the crankshaft until tool (A) can be installed in the crankshaft journal oil passage. Install tool (A).b. Turn the crankshaft in the direction which will push the upper main bearing out, tab end first.c. Check the condition of the bearings. (See Guideline For Reusable Parts, Main And Connecting Rod Bearings, FORM No. SEBF8009 and SEBD0531). Both the center and two end main journals have no oil hole. To remove these bearings, put a thin piece of soft material, (that will not damage the crankshaft journal), against the end of the bearing opposite the tab. Hit the bearing with the soft material until the tab of the bearing is free from the groove in the block. The following steps are for the installation of the crankshaft main bearings. Put clean engine oil on the main bearings for the assembly. Also, be sure the tabs on the back side of the main bearings fit in the grooves of the main bearing caps and cylinder block.3. Clean the surfaces in the cylinder block for the main bearings. Use tool (A), and install new upper halves of main bearing (bearings with the oil hole) in the cylinder block. Do not put oil on the back of the bearing.4. Clean the surface of the main bearing caps for the main bearings. Install the new lower halves of the main bearings in the main caps. Do not put oil on the back of the bearing.
Install the main bearing caps with the sequence number to the right, 1 through 7, front to rear.
5. Put main bearing caps (2) in position on the cylinder block. Put engine oil on the bolt threads and the contact surfaces of the bolt heads, and install the bolts. Tighten the bolts on the side where the main bearing tabs are located to a torque of 54 7 N m (40 5 lb.ft.). Tighten the bolts on the opposite side to a torque of 54 7 N m (40 5 lb.ft.).6. Put a mark on each bolt head and the bearing caps. Turn the bolts that are opposite the main bearing tabs an additional 90° 5° turn. Then turn the bolts on the side where the main bearing tabs are located an additional 90° 5° turn. 8. Check the end play of the crankshaft with a dial indicator and magnetic base. The end play must be 0.07 to 0.24 mm (.003 to .009 in.). The end play is controlled by the thrust bearings, which are part of main bearing No. six.End By:a. install oil pumpb. install oil pan
If the crankshaft is turned in the wrong direction, the tab of the bearing will be pushed between the crankshaft and cylinder block. This can cause damage to either or both the crankshaft and the block.
2. Remove the upper half of the main bearings as follows:a. Turn the crankshaft until tool (A) can be installed in the crankshaft journal oil passage. Install tool (A).b. Turn the crankshaft in the direction which will push the upper main bearing out, tab end first.c. Check the condition of the bearings. (See Guideline For Reusable Parts, Main And Connecting Rod Bearings, FORM No. SEBF8009 and SEBD0531). Both the center and two end main journals have no oil hole. To remove these bearings, put a thin piece of soft material, (that will not damage the crankshaft journal), against the end of the bearing opposite the tab. Hit the bearing with the soft material until the tab of the bearing is free from the groove in the block. The following steps are for the installation of the crankshaft main bearings. Put clean engine oil on the main bearings for the assembly. Also, be sure the tabs on the back side of the main bearings fit in the grooves of the main bearing caps and cylinder block.3. Clean the surfaces in the cylinder block for the main bearings. Use tool (A), and install new upper halves of main bearing (bearings with the oil hole) in the cylinder block. Do not put oil on the back of the bearing.4. Clean the surface of the main bearing caps for the main bearings. Install the new lower halves of the main bearings in the main caps. Do not put oil on the back of the bearing.
Install the main bearing caps with the sequence number to the right, 1 through 7, front to rear.
5. Put main bearing caps (2) in position on the cylinder block. Put engine oil on the bolt threads and the contact surfaces of the bolt heads, and install the bolts. Tighten the bolts on the side where the main bearing tabs are located to a torque of 54 7 N m (40 5 lb.ft.). Tighten the bolts on the opposite side to a torque of 54 7 N m (40 5 lb.ft.).6. Put a mark on each bolt head and the bearing caps. Turn the bolts that are opposite the main bearing tabs an additional 90° 5° turn. Then turn the bolts on the side where the main bearing tabs are located an additional 90° 5° turn. 8. Check the end play of the crankshaft with a dial indicator and magnetic base. The end play must be 0.07 to 0.24 mm (.003 to .009 in.). The end play is controlled by the thrust bearings, which are part of main bearing No. six.End By:a. install oil pumpb. install oil pan