101433-9210 ZEXEL 9 400 610 064 BOSCH INJECTION-PUMP ASSEMBLY 9400610064 1014339210 16700l2500

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 064 9400610064

ZEXEL 101433-9210 1014339210

NISSAN-DIESEL 16700L2500 16700l2500

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Service parts 101433-9210 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101043-8470

3. GOVERNOR 105520-3111

4. SUPPLY PUMP 105220-4030

5. AUTOM. ADVANCE MECHANIS 105622-0240

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105141-1800

11. Nozzle and Holder 16600-90019

12. Open Pre:MPa(Kqf/cm2) 9.8{100}

13. NOZZLE-HOLDER 105071-1240

14. NOZZLE

105000-1010

15. NOZZLE SET

Include in #1:

101433-9210 as INJECTION-PUMP ASSEMBLY

Include in #2:

105856-1741 as _

Cross reference number

BOSCH 9 400 610 064 9400610064

ZEXEL 101433-9210 1014339210

NISSAN-DIESEL 16700L2500 16700l2500

Zexel num

Bosch num

Firm num

Name

101433-9210

9 400 610 064

16700L2500 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
SD22 * K 14BC PE4A,5A, PE

Calibration Data:

Adjustment conditions

Test oil
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

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 2.3 2.25 2.35

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point -

Rack position 14.9

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 36.6 35.6 37.6

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point -

Rack position 13.9

Pump speed r/min 1700 1700 1700

Average injection quantity mm3/st. 36.6 35 38.2

Max. variation between cylinders % 0 -4 4

Fixing the rack *

Injection quantity adjustment_03

Adjusting point -

Rack position 9

Pump speed r/min 1700 1700 1700

Average injection quantity mm3/st. 7 6.2 7.8

Max. variation between cylinders % 0 -7.5 7.5

Fixing the rack *

Injection quantity adjustment_04

Adjusting point -

Rack position 10.8

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 7.5 6.4 8.6

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Timer adjustment

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 550

Advance angle deg. 0.7

Timer adjustment_03

Pump speed r/min 700

Advance angle deg. 1 0.5 1.5

Timer adjustment_04

Pump speed r/min 900

Advance angle deg. 2 1.5 2.5

Timer adjustment_05

Pump speed r/min 1100

Advance angle deg. 3 2.5 3.5

Timer adjustment_06

Pump speed r/min 1300

Advance angle deg. 4 3.5 4.5

Timer adjustment_07

Pump speed r/min 1500

Advance angle deg. 5 4.5 5.5

Remarks
Finish

Test data Ex:

Governor adjustment

P:Negative pressure R:Rack position (mm) (1)Pneumatic governor
----------

----------

0000001101

S:Stop N:Normal B:When boosted (1)Rack position = approximately aa. (2)Rack position corresponding to bb
----------
aa=3.5mm bb=21mm
----------
a=24.5deg b=12deg c=4deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'Y' at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(130deg)

Information:

3. Turn the engine to the top center (TC) compression stroke for the No. 1 piston.4. Remove bolts (1), cover assembly (2) and the gasket from the front housing. 5. Remove two bolts (3). Carefully remove thrust plate (4) and the camshaft assembly from the engine.6. Remove drive gear (5) from the camshaft with a press. Remove the woodruff key from the camshaft. The following steps are for the installation of the camshaft.7. Install the woodruff key in the camshaft. Heat drive gear (5) to a maximum temperature of 316°C (600°F). Do not use a torch to heat the drive gear. Install the drive gear on the camshaft, and allow it to cool.
Camshaft timing is very important. When the camshaft assembly is installed, be sure the No. 1 piston is at top center (TC) of the compression stroke. The timing marks on the camshaft drive gear, the idler gear and the crankshaft idler gear must be in alignment as shown in Illustration C21075P5. For more information regarding timing of the engine, see the topic "Front Gear Group" in the 3114 & 3116 Diesel Truck Engine Specifications module, Form No. SENR6436.
8. Apply clean engine oil on the lobes and journals of the camshaft. Carefully install the camshaft assembly in the cylinder block.9. Put thrust plate (4) in position, and install bolts (3) that hold it.10. Be sure the mating surfaces of the front housing and cover assembly (2) are thoroughly clean. Apply 8C8422 Sealant to the cover assembly sealing surface. Spread the sealant uniformly and around each bolt hole. The cover assembly must be installed on the front housing within ten minutes of sealant application.11. Put the gasket and cover assembly (2) in position on the front housing. Install bolts (1) that hold the cover assembly to the front housing.12. Install the vibration damper and the crankshaft pulley. See the topic "Remove & Install Vibration Damper, Crankshaft Pulley & Crankshaft Front Seal" in this module.13. Install the governor and fuel transfer pump. See the topic "Remove & Install Governor & Fuel Transfer Pump" in this module.End By:a. Install lifter assemblies