Information injection-pump assembly
ZEXEL
106671-6121
1066716121
ISUZU
1156031151
1156031151
Rating:
Cross reference number
ZEXEL
106671-6121
1066716121
ISUZU
1156031151
1156031151
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
105780-8250
Bosch type code
1 688 901 101
Nozzle
105780-0120
Bosch type code
1 688 901 990
Nozzle holder
105780-2190
Opening pressure
MPa
20.7
Opening pressure
kgf/cm2
211
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
134424-4320
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
Tester oil delivery pressure
kPa
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
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
1-5-3-6-
2-4
Pre-stroke
mm
5.2
5.17
5.23
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.75 60.25
Cal 1-5 deg. 60 59.75 60.25
Difference between angles 2
Cal 1-3 deg. 120 119.75 120.25
Cal 1-3 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
Cyl.1-2 deg. 240 239.75 240.25
Cyl.1-2 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-4 deg. 300 299.75 300.25
Cal 1-4 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
-
Rack position
11.9
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
116.5
114.5
118.5
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
6.5+-0.5
Pump speed
r/min
440
440
440
Average injection quantity
mm3/st.
15
11.8
18.2
Max. variation between cylinders
%
0
-13
13
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.9)
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
116.5
114.5
118.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
36
36
Boost pressure
mmHg
270
270
Injection quantity adjustment_04
Adjusting point
B
Rack position
(R1-0.05
)
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
133.5
127.5
139.5
Fixing the lever
*
Boost pressure
kPa
36
36
Boost pressure
mmHg
270
270
Boost compensator adjustment
Pump speed
r/min
430
430
430
Rack position
R2-1.7
Boost pressure
kPa
7.3
6
8.6
Boost pressure
mmHg
55
45
65
Boost compensator adjustment_02
Pump speed
r/min
430
430
430
Rack position
R2(R1-0.
6)
Boost pressure
kPa
22.7
22.7
22.7
Boost pressure
mmHg
170
170
170
Timer adjustment
Pump speed
r/min
850--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
800
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
950
Advance angle
deg.
2
1.5
2.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Boost compensator stroke: BCL
(4)Damper spring setting
----------
T1=AE57 BCL=1.7+-0.1mm
----------
----------
T1=AE57 BCL=1.7+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the pin at R = aa
(2)Stopper bolt set position 'H'
----------
aa=32mm
----------
a=4deg+-5deg b=30.5deg+-3deg
----------
aa=32mm
----------
a=4deg+-5deg b=30.5deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the pin at R = aa
(2)Set the stopper bolt so that speed = bb and rack position = cc. (Confirm non-injection.)
----------
aa=40mm bb=0r/min cc=1+-0.3mm
----------
a=18deg+-5deg b=44deg+-5deg
----------
aa=40mm bb=0r/min cc=1+-0.3mm
----------
a=18deg+-5deg b=44deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of timer's threaded hole at the No. 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=14deg
----------
a=(100deg)
----------
aa=14deg
----------
a=(100deg)
Information:
Tooling and Equipment
The tools shown in Chart F, Tooling for Finding Top Center (TC) Position, are required to complete the procedure.
Table 8
Chart F
Tooling For Finding Top Center (TC) Position
Part No Description Qty Item (1)
8T-4177 Bolt, Spring Compressor 1 7
( 1 ) Refer to the nomenclature chart at the beginning of this manual for item identification.Procedure
Illustration 39 g03425683
Timing Bolt Location (35) 8T-4177 Timing Bolt (36) Timing Hole (37) Flywheel HousingNote: Depending on engine application, timing hole (36) is located at either the left front face or the right front face of the flywheel housing.
Remove plug from the timing hole (36) on the front of the flywheel housing.
Rotate the engine with four large bolts on the front of the crankshaft. Do not use the eight small bolts on the front of the crankshaft pulley as this could cause damage to the engine.
Put 8T-4177 Bolt (35) in hole. Turn the engine flywheel counterclockwise until the timing bolt engages with the threaded hole in the flywheel.Note: If the flywheel is turned beyond the point the timing bolt engages in the threaded hole, the flywheel must be turned back at least 30 degrees clockwise. Again, turn the flywheel counterclockwise until the timing bolt engages with the threaded hole. This procedure makes sure that the play is removed from the gears when number 1 piston is put on TC.
Remove the cylinder head valve cover.
Illustration 40 g03425694
Valve Cover Removed
The intake and the exhaust valves for the number 1 cylinder are fully closed if number 1 piston is on the compression stroke and the rocker arms can be moved by hand. If the rocker arms cannot be moved and the valves are slightly open, the number 1 piston is on the exhaust strike. Refer to Chart E, Crankshaft Positions for Fuel Timing Settings, to determine which cylinders can be checked/adjusted (determined by stroke position of crankshaft when timing bolt is installed).Note: When the actual stroke position is identified, and the other stroke position is desired, it is necessary to remove the timing bolt from the flywheel. Turn the flywheel counterclockwise 360 degrees, and reinstall the timing bolt.
After TC position for a particular stroke is obtained and adjustments are made, remove the timing bolt and turn the flywheel counterclockwise 360 degrees. This will put number 1 piston at TC position on the other stroke. Install timing bolt in the flywheel and complete adjustments for remaining cylinders.Removal and Installation of Unit Fuel Injectors
Table 9
Chart G
Injector Removal and Installation Tools
Part No Description Qty Item (1)
5P-0302 Injector Removal Bar 1 16
194-3542 Hex Socket Bit Driver, 5 mm 1 18
( 1 ) Refer to nomenclature chart, at the beginning of this manual for item identification.
Illustration 41 g03425701
Unit Fuel Injector (48) Bolt (49) O-RingsNote: Not all injectors use a bottom O-ring.Removal
Remove injector hold down bolt (48) .
Do not pry on the injector hold down bracket.
The tools shown in Chart F, Tooling for Finding Top Center (TC) Position, are required to complete the procedure.
Table 8
Chart F
Tooling For Finding Top Center (TC) Position
Part No Description Qty Item (1)
8T-4177 Bolt, Spring Compressor 1 7
( 1 ) Refer to the nomenclature chart at the beginning of this manual for item identification.Procedure
Illustration 39 g03425683
Timing Bolt Location (35) 8T-4177 Timing Bolt (36) Timing Hole (37) Flywheel HousingNote: Depending on engine application, timing hole (36) is located at either the left front face or the right front face of the flywheel housing.
Remove plug from the timing hole (36) on the front of the flywheel housing.
Rotate the engine with four large bolts on the front of the crankshaft. Do not use the eight small bolts on the front of the crankshaft pulley as this could cause damage to the engine.
Put 8T-4177 Bolt (35) in hole. Turn the engine flywheel counterclockwise until the timing bolt engages with the threaded hole in the flywheel.Note: If the flywheel is turned beyond the point the timing bolt engages in the threaded hole, the flywheel must be turned back at least 30 degrees clockwise. Again, turn the flywheel counterclockwise until the timing bolt engages with the threaded hole. This procedure makes sure that the play is removed from the gears when number 1 piston is put on TC.
Remove the cylinder head valve cover.
Illustration 40 g03425694
Valve Cover Removed
The intake and the exhaust valves for the number 1 cylinder are fully closed if number 1 piston is on the compression stroke and the rocker arms can be moved by hand. If the rocker arms cannot be moved and the valves are slightly open, the number 1 piston is on the exhaust strike. Refer to Chart E, Crankshaft Positions for Fuel Timing Settings, to determine which cylinders can be checked/adjusted (determined by stroke position of crankshaft when timing bolt is installed).Note: When the actual stroke position is identified, and the other stroke position is desired, it is necessary to remove the timing bolt from the flywheel. Turn the flywheel counterclockwise 360 degrees, and reinstall the timing bolt.
After TC position for a particular stroke is obtained and adjustments are made, remove the timing bolt and turn the flywheel counterclockwise 360 degrees. This will put number 1 piston at TC position on the other stroke. Install timing bolt in the flywheel and complete adjustments for remaining cylinders.Removal and Installation of Unit Fuel Injectors
Table 9
Chart G
Injector Removal and Installation Tools
Part No Description Qty Item (1)
5P-0302 Injector Removal Bar 1 16
194-3542 Hex Socket Bit Driver, 5 mm 1 18
( 1 ) Refer to nomenclature chart, at the beginning of this manual for item identification.
Illustration 41 g03425701
Unit Fuel Injector (48) Bolt (49) O-RingsNote: Not all injectors use a bottom O-ring.Removal
Remove injector hold down bolt (48) .
Do not pry on the injector hold down bracket.