106689-4000 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066894000 m141400100z

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106689-4000 1066894000

DAIHATSU M141400100Z m141400100z

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Cross reference number

ZEXEL 106689-4000 1066894000

DAIHATSU M141400100Z m141400100z

Zexel num

Bosch num

Firm num

Name

106689-4000

M141400100Z DAIHATSU

INJECTION-PUMP ASSEMBLY
M3S * K

Calibration Data:

Adjustment conditions

Test oil
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 8-3-600

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-4-2-6- 3-5

Pre-stroke mm 2.5 2.45 2.55

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 -

Rack position 13

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 348 339 357

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point -

Rack position 5.5+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 30 27 33

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Injection quantity adjustment_03

Remarks
Rack limit setting R = 14.4+-0.1

Timer adjustment

Pump speed r/min 650--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 600

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 750

Advance angle deg. 2.1 1.6 2.6

Timer adjustment_04

Pump speed r/min 900

Advance angle deg. 5 4.5 5.5

Remarks
Finish

Test data Ex:

Timing setting

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

----------
a=(7deg)

Information:

(1) End play for shaft (new) ... 0.102 0.025 mm (.004 .001 in) Maximum permissible end play (worn) ... 0.20 mm (.008 in)(2) Thickness of thrust bearing (where thrust rings contact bearing) ... 5.36 0.03 mm (.211 .001 in)(3) Diameter of shaft (new) ... 12.697 to 12.705 mm (.4999 to .5002 in) Bore in the bearing (new) ... 12.741 to 12.748 mm (.5016 to .5019 in)Maximum permissible clearance between bearing and shaft (worn) ... 0.05 mm (.002 in)(4) Maximum permissible gap of oil seal ring, measured in bore of housing ... 0.25 mm (.010 in)(5) Install the compressor wheel (at room temperature) as follows: a. Put compressor wheel on the shaft.b. Put a small amount of clean engine oil on the threads.c. Tighten the nut to 14 to 17 N m (125 to 150 lb in).d. Remove nut from shaft and apply 6V1541 Quick Cure Primer on the threads of the shaft and nut followed by application of 9S3263 Retaining Compound.e. Tighten nut to a torque of ... 24 2 N m (216 12 lb in)(6) Thickness of each thrust ring ... 2.553 0.013 mm (.1005 .0005 in)(7) Bore in housing (new) ... 20.744 to 20.757 mm (.8167 to .8172 in) Outside diameter of the bearing (new) ... 20.630 to 20.643 mm (.8122 to .8127 in)Maximum permissible clearance between bearing and bore in housing (worn) ... 0.15 mm (.006 in)Torque for four nuts (put 5P3931 Anti-Seize Compound on threads) and bolts that hold turbocharger to exhaust manifold ... 55 5 N m (40 4 lb ft)Install the band clamps to hold the cartridge to the compressor housing as follows: a. Tighten clamps to ... 14 1.1 N m (125 10 lb in)b. Tap (hit) clamp lightly all around.c. Tighten again to ... 14 1.1 N m (125 10 lb in) Put clean engine oil in the oil inlet of the turbocharger after assembly or before installation to provide start up lubrication and/or storage protection.Schwitzer S2BG
(1) Clearance between ends of oil seal ring (when installed in bore) ... 0.05 to 0.25 mm (.002 to .010 in)(2) Apply 5P3931 Anti-Seize Compound to threads of bolts that hold turbine housing to turbocharger. Tighten to a torque of ... 15.8 0.5 N m (140 5 lb in)(3) Tighten bolts that hold compressor housing to turbocharger cartridge to a torque of ... 7.3 0.5 N m (65 5 lb in)(4) Compressor wheel installation: a. Install wheel on shaft.b. Put 1 drop of 7M7456 Bearing Mount on shaft threads.c. Tighten nut to a torque of ... 10.2 0.5 N m (90 5 lb in)(5) End play for shaft ... 0.051 to 0.083 mm (.0020 to .0033 in)(6) Apply 5P3931 Anti-Seize Compound. Tighten to a torque of ... 54 5 N m (40 4 lb ft)(7) Bore in housing for bearings ... 17.991