101601-4393 ZEXEL 9 400 614 590 BOSCH INJECTION-PUMP ASSEMBLY 9400614590 1016014393 5156008807

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 614 590 9400614590

ZEXEL 101601-4393 1016014393

ISUZU 5156008807 5156008807

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Buy INJECTION-PUMP ASSEMBLY 101601-4393 zexel genuine, new aftermarket engine parts with delivery

Service parts 101601-4393 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-4840

3. GOVERNOR 105931-9250

4. SUPPLY PUMP 105220-5910

5. AUTOM. ADVANCE MECHANIS 105612-1590

6. COUPLING PLATE 105661-3230

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4582

11. Nozzle and Holder 5-15300-089-1

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105031-3952

14. NOZZLE

105015-4130

15. NOZZLE SET

Include in #1:

101601-4393 as INJECTION-PUMP ASSEMBLY

106672-9770 as _

Cross reference number

BOSCH 9 400 614 590 9400614590

ZEXEL 101601-4393 1016014393

ISUZU 5156008807 5156008807

Zexel num

Bosch num

Firm num

Name

101601-4393

9 400 614 590

5156008807 ISUZU

INJECTION-PUMP ASSEMBLY
6BD1 * 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 132424-0620

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 1-5-3-6- 2-4

Pre-stroke mm 3.6 3.55 3.65

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point -

Rack position 11.6

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 60 58.4 61.6

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 325 325 325

Average injection quantity mm3/st. 9.3 8 10.6

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.6)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 60 59 61

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.15

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 66.5 62.5 70.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1(11.6)

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 62.1 58.9 65.3

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1+0.1

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 47.5 44.3 50.7

Fixing the lever *

Timer adjustment

Pump speed r/min 1000

Advance angle deg. 0.3

Timer adjustment_02

Pump speed r/min 1050

Advance angle deg. 0.7

Timer adjustment_03

Pump speed r/min 1300

Advance angle deg. 1.8 1.3 2.3

Timer adjustment_04

Pump speed r/min 1600

Advance angle deg. 4 3.5 4.5

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. (3)RACK LIMIT: RAL
----------
T1=E58 RAL=(14.5)+0.2mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=39deg+-5deg b=40deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=25deg+-5deg b=40deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(20deg)

Information:

START BY:a. remove valve covers
Do not let the tops of the fuel nozzles turn when the fuel lines are loosened. The nozzles will be damaged if the top of the nozzles turns in the body.
1. Loosen the fuel injection line nut at the nozzle end with tool (A) and a 5P328 crowfoot wrench (7/8").2. Loosen the fuel line nut at the fuel injection line adapter with tool (B). Remove inner fuel injection lines (1). Install caps and plugs on all fuel line openings to keep dirt out of the fuel system. If necessary, use tooling (D) to turn the engine so the valves do not make contact with the pistons when the valves are opened with tool (C) to remove the push rods.3. Put compression on the valve springs with tool (C), and remove push rods (2). Put identification marks on the push rods as to their location in the engine.4. Push the push rod end of the rocker arms down. 5. Remove the intake valve lifter with tooling (E) as follows:a. Install 5P2685 Nut (3) and 5P6601 Collet (4) on 5P2408 Outer Handle Assembly (5).b. Install 5P6599 Inner Handle Assembly (6) in 5P2408 Outer Handle Assembly (5). c. Install tooling (E) in the intake valve lifter. Hold the 5P2408 Outer Handle Assembly, and tighten the 5P6599 Inner Handle Assembly until the 5P6601 Collet is tight against the inside of the intake valve lifter. d. Remove intake valve lifters (7) from the cylinder block with tooling (E). Put identification marks on the lifters as to their location in the engine. 6. Remove the exhaust valve lifters with tooling (E) as follows:a. Install 5P2685 Nut (3) and 5P6601 Collet (4) on 5P2408 Outer Handle Assembly (5). The opening in the cylinder head assembly for the intake valve lifter is larger than the opening in the exhaust valve lifter side. The tooling and each valve lifter must be installed and removed from the intake valve lifter side.b. Install the outer handle assembly in the intake valve lifter side of the cylinder head assembly. Slide the flat area of 5P2408 Outer Handle Assembly (5) through the head casting, and install the 5P6601 Collet in the exhaust valve lifters. c. Install 5P6599 Inner Handle Assembly (6) in 5P2408 Outer Handle Assembly (5). Hold the 5P2408 Handle Assembly, and tighten the 5P6599 Handle Assembly until the 5P6601 Collet is tight against the inside of the exhaust valve lifter.d. Pull the exhaust valve lifter up until the spring on the exhaust valve lifter is free from the cylinder block.e. Remove the 5P6599 Inner Handle Assembly. Slide the 5P2408 Outer Handle Assembly through the head casting, and remove it from the intake valve lifter side of the cylinder head. f. Use a magnet, and remove exhaust valve lifters (8) from the intake valve lifter side of the cylinder head assembly. Put identification marks on the lifters as to their location in the engine.7. Remove the guide springs from the lifters.Install Valve Lifters
Steps 1 and 2