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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
Product Overview
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.
Working Principle
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.
Failure Symptoms
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
⚠️ Critical Inspection Note: ISUZU service manuals require that fuel injection pump plunger assemblies be replaced as a complete set of six to maintain balanced fuel delivery across all cylinders. The injection pump must be calibrated on a test bench after plunger replacement. Always use clean diesel fuel and work in a dust-free environment when servicing fuel injection components.
Technical Specifications
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
OEM Cross-Reference
Type
Number
Primary OEM — Short
8-97041664-0
Primary OEM — Long
8970416640
Zexel Reference
131153-6120
Stamping Number
A740
Product Image
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
Vehicle & Engine Compatibility
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
⚠️ Important Fitment Notes:
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
Features & Benefits
Precision Plunger-to-Barrel Clearance (1-2 microns)
Ensures accurate fuel metering and reliable high-pressure delivery — verified by precision manufacturing specification
Zexel 131153-6120 Reference Standard
Manufactured to Zexel original equipment specifications for reliable performance — verified by cross-reference matching
High-Grade Hardened Alloy Steel
Withstands extreme injection pressures and wear for long service life — verified by material certificate and hardness testing
ISO/TS 16949 Quality System
Full traceability with material certificates and batch inspection reports — third-party certified
Quality Control & Verification
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 & Maintenance
⚠️ IMPORTANT: Fuel injection pump service must be performed by a qualified diesel technician in a clean, dust-free workshop. Always clean the injection pump and surrounding area thoroughly before disassembly. Never reuse old plunger assemblies.
Yimi (Guangzhou) Automotive Parts Co., Ltd.
Located in Guangzhou—the economic and transportation hub of Southern China—we are a specialized supplier and exporter with over 20 years of experience in the automotive parts industry. We focus on the production and sales of high-quality ... Yimi (Guangzhou) Automotive Parts Co., Ltd.
Located in Guangzhou—the economic and transportation hub of Southern China—we are a specialized supplier and exporter with over 20 years of experience in the automotive parts industry. We focus on the production and sales of high-quality ...