101441-9292 ZEXEL 9 400 614 137 BOSCH INJECTION-PUMP ASSEMBLY 9400614137 1014419292 16700v6603

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 614 137 9400614137

ZEXEL 101441-9292 1014419292

NISSAN-DIESEL 16700V6603 16700v6603

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Service parts 101441-9292 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101044-8140

3. GOVERNOR 105542-4012

4. SUPPLY PUMP

105220-5001

5. AUTOM. ADVANCE MECHANIS 105622-1250

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105141-2130

11. Nozzle and Holder 16600-36W00

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

13. NOZZLE-HOLDER 105071-1271

14. NOZZLE

105000-1740

15. NOZZLE SET

Include in #1:

101441-9292 as INJECTION-PUMP ASSEMBLY

Include in #2:

105856-7143 as _

Cross reference number

BOSCH 9 400 614 137 9400614137

ZEXEL 101441-9292 1014419292

NISSAN-DIESEL 16700V6603 16700v6603

Zexel num

Bosch num

Firm num

Name

101441-9292

9 400 614 137

16700V6603 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
SD23 * K 14BC INJECTION PUMP ASSY 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 11.5

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 36.1 35.1 37.1

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point -

Rack position 8.1+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 8 6.9 9.1

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point -

Rack position -

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 36.1 35.6 36.6

Remarks
Set full load.

Timer adjustment

Pump speed r/min 550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1200

Advance angle deg. 2 1.5 2.5

Timer adjustment_04

Pump speed r/min 2150

Advance angle deg. 7 6.5 7.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) P:Negative pressure (1)Pneumatic governor (2)Mechanical governor (3)Acting negative pressure: P1 (4)RACK LIMIT: RAL (5)Beginning of idle sub spring operation: L1 (6)Without stopper disk (7)Injection quantity Q = Q1 or less (at N = N1)
----------
P1=2.55+-0.2kPa(260+-20)mmAq RAL=14.7-0.3mm L1=8.1+0.3mm Q1=3mm3/st N1=(2600)r/min
----------

Speed control lever angle

N:Normal B:When boosted S:Stop (1)Rack position = aa (2)Rack position corresponding to cc
----------
aa=0mm bb=15mm
----------
a=2.5deg+-5deg b=23deg+-3deg c=7deg+-5deg

0000001501 ACS

(N): Speed of the pump (P): governor's negative pressure (Pa): aneroid compensator's negative pressure (A) rubber boot (B) Nut (c) Nut (D) Lever 1. Aneroid compensator installation (1)Turn nut (C) to adjust gap to L1. (Remove rubber boot at adjustment.) (2)Lock using nut (B). (3)After installation, the lever D must move smoothly when the lever D is moved to the excess fuel side, and R = R1 or more.
----------
L1=0.1~0.5mm R1=16mm
----------
N=1000r/min P=0.4kPa(40mmAq) Ra=11.5mm Rb=11.45mm Rc=11.05+-0.2mm Pa1=8-5.3kPa(60-40mmHg) Pa2=16.7kPa(125mmHg) Q1=- Q2=-

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'Y' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=18deg
----------
a=(130deg)

Information:

Illustration 8 g00778880
This is an illustration of the 154-8016 Fuel Injector Seals . (14) Metal Seal (15) 133-3715 Backup Ring (16) 150-4105 Backup Ring (17) 9X-7557 O-Ring Seal (18) 148-2903 O-Ring Seal (19) 149-5240 Backup Ring (20) 109-3207 O-Ring Seal
Illustration 9 g00638512
(A) 149-2955 Seal Protector
Illustration 10 g00638506
(B) 149-2956 Seal Installer
The correct procedures and tooling specifications must always be used. Failure to follow any of the procedures may result in damage, malfunction, or possible engine failure.
Note: Install the upper seal pack first. Then install the middle seal pack. Finally, install the bottom O-Ring Seal.
Both the 149-2955 Seal Protector (A) and the 149-2956 Seal Installer (B) should be used when you are installing the upper high pressure seals.Note: New seals should be installed after each removal of the injector from the engine.
Lubricate the O-Ring seals and the sleeve bore of the injector sparingly with clean engine oil.Note: Proper installation of the injector is very important. Damage to the upper high pressure seals can cause excessive oil leakage under the valve cover. This may cause the engine not to start due to a low actuation pressure. Damage to the lower high pressure seals may allow high pressure oil to leak into the fuel supply passage. This will result in excessive oil consumption.
Illustration 11 g00621566
(X) 8T-2396 Bolts . (Y) 159-0288 Deflector . Note: Some of these engines were built without the 159-0288 Deflector . During the installation of the unit injectors, the deflectors should be installed. Six 159-0288 Deflectors and six 8T-2396 Bolts are required for each engine. These new deflectors and bolts replace the former 6V-8653 Bolts .
Illustration 12 g00294210
Illustration 13 g00312124
(C) 152-1057 Fuel Injector Installer
Carefully install the injector into the injector bore. If access permits you to seat the injector, push the injector straight down on top of the injector's solenoid by hand until the injector is firmly seated in the injector bore. Pushing hard enough to compress the injector's seals may be difficult. If the injector can not be seated by hand, use a 152-1057 Fuel Injector Installer (C). Note: Do NOT pry on the top of the injector with another tool. Do NOT strike the injector with a hammer. Damage to the injector will result. Damage to the injector that is due to improper installation is not a warrantable failure.
Illustration 14 g00778888
(2) Wiring Harness Connection (3) Clamp (10) Shoulder Bolt (11) Socket Head BoltNote: Do not use the shoulder bolt and the socket head bolt in order to seat the injector. If a side load is placed on the bolts, the bolts may fail.
After the injector is seated, position the clamp (2) and tighten the Shoulder Bolt (10) to a torque of 6 N m (50 lb in). Then tighten the Socket Head Bolt (11) to a torque of 12 N m (9 lb ft).
Insert the harness connectors (2) back into the injectors' solenoids. Ensure that the clips are snapped back into