ISUZU 6BG1 6BG1T High-Grade Alloy Steel Fuel Pump Plunger Assembly with 1–2 Microns Clearance OEM Fit
| Net Weight: | Approx. 0.15 Kg | Plunger Type: | Inline Pump Element, Helical Groove Control |
| Plunger-to-Barrel Clearance: | Approx. 1–2 Microns | Engine Compatibility: | 6BG1 / 6BG1T (6.5L, 6-cylinder, DI) |
| Material: | High-Grade Alloy Steel (Hardened) | OEM Part Number: | 8-97041664-0 / 8970416640 |
| Stamping Number: | A740 | Zexel Reference: | 131153-6120 |
| High Light: | High-Grade Alloy Steel Fuel Pump Plunger Assembly,1–2 Microns Clearance Pump Element,OEM Fit Fuel Injection Pump Plunger Assembly |
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Fuel Injection Pump Plunger Assembly 8-97041664-0 8970416640 A740 for ISUZU 6BG1 6BG1T — Verified OEM Fit Zexel 131153-6120 Diesel Pump Element
The Fuel Injection Pump Plunger Assembly with OEM numbers 8-97041664-0 and 8970416640 — also referenced as A740 and Zexel 131153-6120 — is a verified direct-fit replacement for ISUZU 6BG1 / 6BG1T diesel engines and Hitachi EX200-5 / EX210LC-5 excavators. This precision component of the inline fuel injection pump is responsible for pressurizing and delivering exact quantities of diesel fuel to each cylinder at the precise moment required for combustion.
The fuel injection pump plunger assembly is the heart of the diesel injection system. It consists of a precision-matched plunger and barrel pair that reciprocates inside the pump housing. As the plunger moves upward on its camshaft-driven stroke, it pressurizes the fuel in the barrel to injection pressure. The helical groove on the plunger controls the effective stroke, determining the quantity of fuel delivered to the injector.
The A740 plunger assembly is manufactured to micron-level tolerances, with a plunger-to-barrel clearance of approximately 1-2 microns, ensuring precise fuel metering and reliable high-pressure delivery. The ISUZU 6BG1 is a 6.5L inline-six direct-injection diesel engine widely used in ISUZU Forward trucks and Hitachi excavators from the 1990s onwards.
- Engine misfiring or rough running — worn plunger assemblies cause uneven fuel delivery, resulting in rough operation and vibration
- Loss of engine power — insufficient fuel delivery reduces engine power output and acceleration
- Excessive black smoke — poor fuel atomization from a worn plunger leads to incomplete combustion
- Hard starting or no-start — severely worn plungers cannot build sufficient injection pressure for cold starting
- Fuel dilution in engine oil — internal leakage past worn plunger assemblies allows diesel to enter the lubricating oil
- Metal debris in the fuel system — plunger seizure or excessive wear produces metal particles that contaminate the fuel system
| Verification Item | Data / Standard | Source / Method |
|---|---|---|
| Part Number (Short) | 8-97041664-0 | ISUZU OEM Parts Database |
| Part Number (Long) | 8970416640 | ISUZU OEM Parts Database |
| Zexel Reference | 131153-6120 | Zexel parts database |
| Stamping Number | A740 | Pioneer Diesel Parts specification |
| Engine Compatibility | 6BG1 / 6BG1T (6.5L, 6-cylinder, DI) | ISUZU application catalog |
| Plunger-to-Barrel Clearance | Approx. 1-2 microns | Precision manufacturing specification |
| Material | High-Grade Alloy Steel (Hardened) | Material certificate |
| Net Weight (per unit) | Approx. 0.15 kg | Product specification |
| Warranty | 12 Months | Manufacturer standard |
| Certification | ISO/TS 16949 | Third-party system audit |
| Type | Number |
|---|---|
| Primary OEM — Short | 8-97041664-0 |
| Primary OEM — Long | 8970416640 |
| Zexel Reference | 131153-6120 |
| Stamping Number | A740 |
| Part Number: | 8-97041664-0 8970416640 | Product Name: | Fuel Pump Plunger Assembly |
| Car Model: | 6BG1 6BG1T | Engine Model: | 6BG1 6BG1T |
| Condition: | 100% Brand New | Origin: | China Mainland |
Primary Applications:
| Brand | Model | Chassis | Engine | Years |
|---|---|---|---|---|
| ISUZU | Forward | FVR / FSR / FTR | 6BG1 / 6BG1T | 1990s-2000s |
| ISUZU | Forward | FRR / FSS / FTS | 6BG1 / 6BG1T | 1990s-2000s |
| ISUZU | NPR | NPR75 | 6BG1 | 1990s-2000s |
| ISUZU | GIGA | — | 6BG1 / 6BG1T | 1990s-2000s |
Non-ISUZU Applications (Same Engine Platform):
| Brand | Model | Application |
|---|---|---|
| Hitachi | EX200-5 | Excavator |
| Hitachi | EX210LC-5 | Excavator |
- This plunger assembly is designed for the 6BG1 / 6BG1T engine family. Confirm your specific engine model and injection pump type before ordering
- Plunger assemblies should be replaced as a complete set of six to maintain balanced fuel delivery
- For right-hand drive (RHD) vehicles, verify clearance and orientation. Refer to the ISUZU workshop manual for the correct procedure
Ensures accurate fuel metering and reliable high-pressure delivery — verified by precision manufacturing specification
Manufactured to Zexel original equipment specifications for reliable performance — verified by cross-reference matching
Withstands extreme injection pressures and wear for long service life — verified by material certificate and hardness testing
Full traceability with material certificates and batch inspection reports — third-party certified
| QC Item | Verification Method / Standard |
|---|---|
| Plunger Diameter | Micrometer, 100% inspection |
| Barrel Bore Diameter | CMM, 100% inspection |
| Plunger-to-Barrel Clearance | Air gauge, 100% inspection |
| Surface Hardness | Rockwell hardness tester, batch sampling |
| Material Composition | Spectrometer analysis, batch sampling |
| Leakage Test | High-pressure leakage test, 100% inspection |
Installation Guidelines — Reference ISUZU 6BG1 Workshop Manual:
- Preparation: Clean the injection pump exterior thoroughly. Remove the pump from the engine and mount it on a clean workbench
- Disassembly: Remove the old plunger assemblies using a proper plunger puller. Take care not to damage the barrel bores
- Inspection: Inspect the pump housing barrel bores for wear, scoring, or corrosion. Replace any damaged components
- Cleaning: Clean all components with clean diesel fuel or approved injection pump cleaner. Blow dry with compressed air
- Installation: Install the new plunger assemblies with the helical groove facing the correct direction
- Calibration: Mount the injection pump on a calibration test bench. Calibrate the fuel delivery quantity and timing to ISUZU specifications
Maintenance Schedule:
- Every 10,000 km: Check for fuel leaks and abnormal exhaust smoke. Monitor fuel consumption
- Every 40,000-50,000 km: Test injection pump delivery quantity and timing. Replace plunger assemblies if wear is detected
- Every 100,000 km: Replace fuel injection pump plunger assemblies as preventive maintenance
- Standard Packaging: Anti-rust oil + VCI film + neutral carton
- Custom Packaging: Neutral box, color box, or customer-branded packaging available
- Suitable For: Diesel injection repair shops, ISUZU parts distributors, fleet maintenance centers, construction equipment repair shops
- Minimum Order Quantity: 6 PCS (complete set for 6-cylinder engine)
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