Information injection-pump assembly
ZEXEL
106682-1020
1066821020
ISUZU
1156033040
1156033040
Rating:
Cross reference number
ZEXEL
106682-1020
1066821020
ISUZU
1156033040
1156033040
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
105780-8130
Bosch type code
EFEP215A
Nozzle
105780-0050
Bosch type code
DN6TD119NP1T
Nozzle holder
105780-2090
Bosch type code
EFEP215
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-4-1000
Outer diameter - inner diameter - length (mm) mm 8-4-1000
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
2.8
2.75
2.85
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
12.9
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
535
530
540
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
160
160
Boost pressure
mmHg
1200
1200
Injection quantity adjustment_02
Adjusting point
B
Rack position
4.8+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
10.5
7.3
13.7
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
250
250
290
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
800
800
800
Rack position
9.6
Boost pressure
kPa
73.3
70.6
76
Boost pressure
mmHg
550
530
570
Boost compensator adjustment_02
Pump speed
r/min
800
800
800
Rack position
(12.9)
Boost pressure
kPa
147
147
147
Boost pressure
mmHg
1100
1100
1100
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Tolerance for racks not indicated: +-0.05mm.
(2)Boost compensator stroke: BCL
(3)Main spring setting
(4)Set idle sub-spring
----------
BCL=(3.3)mm
----------
----------
BCL=(3.3)mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
(2)Use the hole at R = aa
----------
aa=135mm
----------
a=(5.5deg)+-5deg b=(15.5deg)+-5deg
----------
aa=135mm
----------
a=(5.5deg)+-5deg b=(15.5deg)+-5deg
0000000901
F:Full load
(1)Fix using the stopper bolt.
----------
----------
a=15deg+-5deg
----------
----------
a=15deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=27deg+-5deg b=71deg+-5deg
----------
----------
a=27deg+-5deg b=71deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of coupling's threaded hole at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(30deg)
----------
----------
a=(30deg)
Information:
(1) Thickness of top plate ... .338 .001 in.(8.59 0.03 mm) Thickness of gasket that is placed between top plate and cylinder block ... .008 .001 in.(0.20 0.03 mm)Height of liner over top plate, under installation pressure ... .005 .003 in.(0.13 0.08 mm)(2) Height of dowels above top surface of cylinder block ... .73 in.(18.5 mm)(3) Dimension (new) from centerline of crankshaft bearing bore to top of block (top deck) ... 16.750 .006 in.(425.45 0.15 mm)(4) Bore in block for camshaft bearings ... 3.0250 .0007 in.(76.835 0.018 mm)(5) Bore in the block for the main bearings: standard, original size (new) ... 5.1138 .0005 in.(129.891 0.013 mm).025 in. (0.64 mm) larger than original size ... 5.1388 .0005 in.(130.526 0.013 mm)(6) Distance from front or rear face of cylinder block to end of dowels ... .75 in.(19.1 mm)(7) Width of main bearing cap ... 8.5000 .0005 in.(215.900 0.013 mm) Width of block for main bearing cap ... 8.5000 .0005 in.(215.900 0.013 mm)Clearance between main bearing cap and cylinder block ... .001 in.(0.03 mm) tight to ... .001 in.(0.03 mm) loose
Tightening Procedure For Main Bearings(8) Torque for the bolts that hold the caps for the main bearings: Install the main bearing caps with the marks (arrow) toward the front of the engine. Install each cap in the correct position by putting the number stamped on the bottom of the cap toward the corresponding number on the cylinder block.a. Put engine oil on the threads of the bolts.b. Tighten the bolts first on the tab side of the cap to ... 190 10 lb. ft.(260 14 N m)c. Tighten the bolts on the opposite side to ... 190 10 lb. ft.(260 14 N m)d. Put a mark on each bolt and cap as shown.e. Tighten the bolts on the opposite side, from the mark ... 120°f. Tighten the bolts on the tab side of the cap, from the mark ... 120°(9) Dimension (new) from centerline of crankshaft bearing bore to bottom of block (pan rails) ... 6.500 .004 in.(165.10 0.10 mm) (10) Put 9S3264 Pipe Sealant on threads of 14 plugs before installation in the cylinder block.(11) Torque for bolts holding oil jet cooling tubes (later engines) ... 18 5 lb. ft.(24 7 N m)
Tightening Procedure For Main Bearings(8) Torque for the bolts that hold the caps for the main bearings: Install the main bearing caps with the marks (arrow) toward the front of the engine. Install each cap in the correct position by putting the number stamped on the bottom of the cap toward the corresponding number on the cylinder block.a. Put engine oil on the threads of the bolts.b. Tighten the bolts first on the tab side of the cap to ... 190 10 lb. ft.(260 14 N m)c. Tighten the bolts on the opposite side to ... 190 10 lb. ft.(260 14 N m)d. Put a mark on each bolt and cap as shown.e. Tighten the bolts on the opposite side, from the mark ... 120°f. Tighten the bolts on the tab side of the cap, from the mark ... 120°(9) Dimension (new) from centerline of crankshaft bearing bore to bottom of block (pan rails) ... 6.500 .004 in.(165.10 0.10 mm) (10) Put 9S3264 Pipe Sealant on threads of 14 plugs before installation in the cylinder block.(11) Torque for bolts holding oil jet cooling tubes (later engines) ... 18 5 lb. ft.(24 7 N m)