101493-9280 ZEXEL 9 400 614 505 BOSCH INJECTION-PUMP ASSEMBLY 9400614505 1014939280 167000t315

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 614 505 9400614505

ZEXEL 101493-9280 1014939280

NISSAN 167000T315 167000t315

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Service parts 101493-9280 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-9930

3. GOVERNOR 105921-6311

4. SUPPLY PUMP 105220-6020

5. AUTOM. ADVANCE MECHANIS 105671-0410

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5581

11. Nozzle and Holder 16600-0T301

12. Open Pre:MPa(Kqf/cm2) 18.6{190}

13. NOZZLE-HOLDER 105048-3760

14. NOZZLE 105017-1330

15. NOZZLE SET

Include in #1:

101492-3411 as _

101493-9280 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 614 505 9400614505

ZEXEL 101493-9280 1014939280

NISSAN 167000T315 167000t315

Zexel num

Bosch num

Firm num

Name

101493-9280

9 400 614 505

167000T315 NISSAN

INJECTION-PUMP ASSEMBLY
FD46 * K

101493-9280

9 400 614 505

167000T315 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
FD46 * K

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

Overflow valve 131424-1520

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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 3.2 3.15 3.25

Rack position
Point A R=A

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 12.4

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 66 64.4 67.6

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 9.3 7.5 11.1

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.4)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 66 65 67

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.1

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 74 70 78

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.25

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 55 51 59

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 101 85 117

Fixing the lever *

Timer adjustment

Pump speed r/min 900--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 850

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 3.5 3 4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=H39
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=32mm
----------
a=70deg+-5deg b=39deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=12mm
----------
a=29deg+-5deg b=10deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole (position of gear mark 'S') at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=11deg
----------
a=(60deg)

Information:

Introduction
This Special Instruction provides detailed instructions on the installation of the sleeve into the compensator group of the 3408E and 3412E Unit Injector Hydraulic Pump. If leaks are experienced at the joint of the compensator and the adapter block, the 174-8943 Sleeve may be installed to improve sealing. The new press fit sleeve contains the O-ring more securely than the original slip fit sleeve.Note: Engines built prior to the serial number break that contain the new sleeve have a "S" stamped at the end of the part number on the serial number plate of the pump. The reworked part numbers appear as "144-0835-06S". Individual Components
Table 1
Quantity Part Number Part Description
1 174-8943 Sleeve
1 135-2652 O-Ring
1 033-6039 O-Ring
6 9X-7680 O-Ring Necessary Tools
One of the following tools may be used to insert the new sleeve into the compensator group.
A 31.750 mm (1.250 inch) diameter flat plate.
The 1P-0467 Drive Plate from 1P-0510 Driver Group .
An acceptable bearing insertion tool.Removal Of The O-Ring Seals
Illustration 1 g00638376
Remove the four bolts (1) from the compensator (2). Remove the compensator and the adapter. Do not adjust the compensator. Refer to Special Instruction, REHS0192-03, step 3 of procedure for "Disassembly of the 144-0835 Unit Injector Hydraulic Pump Group ".
Illustration 2 g00638368
Remove the four O-ring seals (3) from the bottom side of the adapter. Refer to Special Instruction, REHS0192-03, step 4 of procedure for "Disassembly of the 144-0835 Unit Injector Hydraulic Pump Group ".
Illustration 3 g00638372
Remove the four O-ring seals (4) from the two housings. Refer to Special Instruction, REHS0192-03, step 5 of procedure for "Disassembly of the 144-0835 Unit Injector Hydraulic Pump Group ".
Remove the slip fit sleeve from the compensator housing.Installation Of The Sleeve
Illustration 4 g00637918
(1) Compensator assembly. (2) 174-8943 Sleeve .
Invert the compensator assembly (1). Hold the compensator assembly securely within a vise or a press table.
Start the sleeve (2) by hand into the compensator assembly (1) .Note: It is important that the groove on the outside diameter of the sleeve is oriented toward the O-ring in the joint. If this is not done, there will not be sufficient room to properly seal the O-ring.
Press the sleeve (2) flush with the surface of the compensator assembly (1) using the 1P-0467 Drive Plate or by using an acceptable bearing insertion tool.Installation Of The O-Ring Seals
Illustration 5 g00638368
Install the four O-ring seals (3) on the bottom side of the adapter. Refer to Special Instruction, REHS0192-03, step 16 of procedure for "Assembly of the 144-0835 Unit Injector Hydraulic Pump Group ".
Illustration 6 g00638372
Install the four O-rings (4) on the two housings. Refer to Special Instruction, REHS0192-03, step 17 of procedure for "Assembly of the 144-0835 Unit Injector Hydraulic Pump Group ".
Illustration 7 g00638376
Install the compensator assembly (2) and the adapter as a unit vertically so that the O-rings seals are not damaged. Tighten the four bolts (1) to the following torque.Torque for bolts ... 8 1 N