Information injection-pump assembly
BOSCH
9 400 612 064
9400612064
ZEXEL
101431-4020
1014314020
ISUZU
8944457490
8944457490
Rating:
Service parts 101431-4020 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
5-15300-039-1
12.
Open Pre:MPa(Kqf/cm2)
11.8{120}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 612 064
9400612064
ZEXEL
101431-4020
1014314020
ISUZU
8944457490
8944457490
Zexel num
Bosch num
Firm num
Name
101431-4020
9 400 612 064
8944457490 ISUZU
INJECTION-PUMP ASSEMBLY
C240 K 14BC INJECTION PUMP ASSY PE4A,5A, PE
C240 K 14BC INJECTION PUMP ASSY PE4A,5A, PE
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 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-3-4-2
Pre-stroke
mm
2.25
2.2
2.3
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
-
Rack position
12.7
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
36.8
35.8
37.8
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
8.4+-0.5
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
7
5.9
8.1
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Timer adjustment
Pump speed
r/min
500+-50
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
800
Advance angle
deg.
1
0.5
1.5
Timer adjustment_03
Pump speed
r/min
1050
Advance angle
deg.
2
1.2
2.7
Timer adjustment_04
Pump speed
r/min
1500
Advance angle
deg.
4.5
3.9
4.9
Timer adjustment_05
Pump speed
r/min
1750
Advance angle
deg.
6
5.5
6.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
P:Negative pressure
R:Rack position (mm)
(1)Pneumatic governor
(2)Torque control stroke
(3)Beginning of idle sub spring operation: L1
----------
L1=6.5-0.5mm
----------
----------
L1=6.5-0.5mm
----------
0000001101
N:Normal
B:When boosted
S:Stop
(1)Rack position = aa
----------
aa=17.5mm
----------
a=7deg+-5deg b=24.5deg+-5deg c=9deg+-5deg
----------
aa=17.5mm
----------
a=7deg+-5deg b=24.5deg+-5deg c=9deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Gear mark Z for the No. 4 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=16.5deg
----------
a=(60deg)
----------
aa=16.5deg
----------
a=(60deg)
Information:
P-302: Boost Pressure Sensor Calibration
The 3176 Boost Pressure Sensor must be calibrated for a zero boost condition with the engine OFF. Calibration is accomplished electronically without need for manual adjustments.The sensor must be recalibrated whenever the transducer module or ECM has been replaced. Incorrect sensor calibration may result in poor engine response or a Diagnostic Code 25 (Boost Pressure Sensor Fault) or a Diagnostic Code 42 (Check Sensor Calibration).Calibration Procedure:
1. Start engine and warm up to normal operating temperature, then turn key OFF.2. Turn key ON (engine off). The sensor will not calibrate if the engine is running.3. Select the Boost Sensor Calibration screen on the ECAP or DDT (see the Special Instructions included with the ECAP or DDT).4. Wait several seconds for the automatic calibration to occur. The screen will display "Calibrated" when finished.5. If the boost pressure sensor will not calibrate, follow P-225: Boost Pressure Sensor Test.P-303: Throttle Position Sensor Adjustment
The Throttle Position Sensor (TPS) is used to provide a throttle signal to the Electronic Control Module (ECM).Sensor output is a constant frequency signal whose pulse width varies with throttle position. This output signal is referred to as either "Duty Cycle" or a "Pulse Width Modulated (PWM)" signal and is expressed as a percentage. When correctly adjusted, the "Remote Mounted" TPS will produce a "Duty Cycle" signal of 15% to 20% at the low idle throttle position and 80% to 85% at the maximum throttle position. The "Pedal Mounted" TPS will produce a "Duty Cycle" of 10% to 22% at the low idle throttle position and 75% to 90% at the high idle throttle position. This signal is translated by the ECM into a "THROTTLE POSITION" signal of 3% at low idle and 100% at full throttle. Always use "DUTY CYCLE" for sensor adjustment.The Throttle Position Sensor may be one of two types. The "Remote-Mounted" TPS is about the size of a soft drink can and is connected to the throttle pedal by OEM-supplied linkage. It requires adjustment for correct operation (explained in this procedure). The "Pedal-Mounted" TPS is mounted directly to a specific style of throttle pedal and requires no adjustment, and in fact can not be adjusted (this procedure NOT needed). Both sensors provide the same type of signal to the ECM. Step 1. Inspect Throttle LinkageInspect the throttle linkage for loose, bent, broken, missing, or worn components. Also check for interference with the linkage or spring. The throttle linkage should work smoothly without excessive drag and return to a low idle position without assistance in less than 1 second. Repair linkage if needed.Step 2. Adjust At Low Idle PositionA. With key OFF-* Install the 40-Pin Breakout 'T' on the Vehicle Connector (J7/P7).* Connect Pulse Width Modulation Probe (from ECAP/DDT) to the Throttle Signal (Pin 40) of the Breakout 'T'. New Service Program Modules (SPM) allow the "Throttle Duty Cycle" to be read directly from the ECM without using the Pulse Width Modulation Probe. With the new SPM installed on the ECAP,
The 3176 Boost Pressure Sensor must be calibrated for a zero boost condition with the engine OFF. Calibration is accomplished electronically without need for manual adjustments.The sensor must be recalibrated whenever the transducer module or ECM has been replaced. Incorrect sensor calibration may result in poor engine response or a Diagnostic Code 25 (Boost Pressure Sensor Fault) or a Diagnostic Code 42 (Check Sensor Calibration).Calibration Procedure:
1. Start engine and warm up to normal operating temperature, then turn key OFF.2. Turn key ON (engine off). The sensor will not calibrate if the engine is running.3. Select the Boost Sensor Calibration screen on the ECAP or DDT (see the Special Instructions included with the ECAP or DDT).4. Wait several seconds for the automatic calibration to occur. The screen will display "Calibrated" when finished.5. If the boost pressure sensor will not calibrate, follow P-225: Boost Pressure Sensor Test.P-303: Throttle Position Sensor Adjustment
The Throttle Position Sensor (TPS) is used to provide a throttle signal to the Electronic Control Module (ECM).Sensor output is a constant frequency signal whose pulse width varies with throttle position. This output signal is referred to as either "Duty Cycle" or a "Pulse Width Modulated (PWM)" signal and is expressed as a percentage. When correctly adjusted, the "Remote Mounted" TPS will produce a "Duty Cycle" signal of 15% to 20% at the low idle throttle position and 80% to 85% at the maximum throttle position. The "Pedal Mounted" TPS will produce a "Duty Cycle" of 10% to 22% at the low idle throttle position and 75% to 90% at the high idle throttle position. This signal is translated by the ECM into a "THROTTLE POSITION" signal of 3% at low idle and 100% at full throttle. Always use "DUTY CYCLE" for sensor adjustment.The Throttle Position Sensor may be one of two types. The "Remote-Mounted" TPS is about the size of a soft drink can and is connected to the throttle pedal by OEM-supplied linkage. It requires adjustment for correct operation (explained in this procedure). The "Pedal-Mounted" TPS is mounted directly to a specific style of throttle pedal and requires no adjustment, and in fact can not be adjusted (this procedure NOT needed). Both sensors provide the same type of signal to the ECM. Step 1. Inspect Throttle LinkageInspect the throttle linkage for loose, bent, broken, missing, or worn components. Also check for interference with the linkage or spring. The throttle linkage should work smoothly without excessive drag and return to a low idle position without assistance in less than 1 second. Repair linkage if needed.Step 2. Adjust At Low Idle PositionA. With key OFF-* Install the 40-Pin Breakout 'T' on the Vehicle Connector (J7/P7).* Connect Pulse Width Modulation Probe (from ECAP/DDT) to the Throttle Signal (Pin 40) of the Breakout 'T'. New Service Program Modules (SPM) allow the "Throttle Duty Cycle" to be read directly from the ECM without using the Pulse Width Modulation Probe. With the new SPM installed on the ECAP,
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Group cross 101431-4020 ZEXEL
Isuzu
101431-4020
9 400 612 064
8944457490
INJECTION-PUMP ASSEMBLY
C240
C240