SAME SILVER 100.6 - Injection Pump Calibration

Replacement of camshaft or cylinder block
In the event of camshaft or cylinder block replacement, the valve and injection pump timing procedures must be
repeated, but the injection pumps will not require re-calibration.
Install the new pump in the cylinder block with the control rack locked in position, making sure that the dog engages
the control rod and following the instructions on page 74 (pump positioning).
Replacing the injection pumps control rod
Proceed to refit the new rod following the directions on page 74 (pumps), and complete all operations relative to the
positioning of the injection pumps.
Injection pump calibration 2.4619.030.0 2.4619.050.0
and 2.4619.050.0/20 on the BOSCH test bench
Type BOSCH 1 K 90 A 503, type 1 K 90 A 517 and type BOSCH
1 K 9 A 542
Injection pump calibration is of crucial importance to the correct
engine running. Injection pump calibration procedure should be
carried out by specialized workshops provided with the following
BOSCH equipment:
— Injection 2.4719.200.0/10
— Injection pipe Ø 6
X 1,5 X 267
— Test oil ISO 4113 a temp. 40°C
— Fuel supply fuel 0,4
±
0,05 bar
— Camshaft (Special tool) No. 1 688 901 025
— (with 7 mm cam lift)
— Outlet with metering orifice Ø 1 mm
Calibration specifications
test conditions
r.p.m. deviation
from X* in
mm
delivery
mm
3
/lift
1
st
test
750 +3
83
÷
89
2
nd
test
300 +3,5
12,5
÷
13,5
3
nd
test
1300 +3
72
÷
78
4
nd
test
100 +9
78
÷
93
*X - Centre position of the pawl the injection pump obtained with
BOSCH special tool.
Fig. 15 - Injection pump plungers.
Fig. 14 - Injection pump calibration test bench.
Injection pump specifications
— Nominal delivery prelift at X+3 = 2,4÷2,5
— Reflux valve 70 bar
— Depth of start retard notch 0,5 mm
— Retard notch cut-in X+ 7 mm
engine
fuel system
A No fuel delivery, fuel flows back
from the longitudinal groove
B Partial delivery, correct ad-
justment permits fuel backflow with
partial stroke
C Peak delivery, stroke correspon-
ding to maximum fuel delivery
16
1
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