101602-9200 ZEXEL 9 400 611 232 BOSCH INJECTION-PUMP ASSEMBLY 9400611232 1016029200

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 611 232 9400611232

ZEXEL 101602-9200 1016029200

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Buy INJECTION-PUMP ASSEMBLY 101602-9200 zexel genuine, new aftermarket engine parts with delivery

Service parts 101602-9200 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-9010

3. GOVERNOR 105472-0720

4. SUPPLY PUMP 105210-3210

5. AUTOM. ADVANCE MECHANIS 105642-0020

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 18.1{175}

13. NOZZLE-HOLDER

14. NOZZLE

15. NOZZLE SET

Include in #1:

101402-4020 as _

101602-9200 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 611 232 9400611232

ZEXEL 101602-9200 1016029200

Zexel num

Bosch num

Firm num

Name

101602-9200

9 400 611 232

DAEWOO

INJECTION-PUMP ASSEMBLY
D2156 K 14BE INJECTION PUMP ASSY PE6A 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

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 1.75 1.7 1.8

Beginning of injection position
Governor 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 12

Pump speed r/min 800 800 800

Each cylinder's injection qty mm3/st. 112.5 111 114

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point -

Rack position 7.4+-0.5

Pump speed r/min 200 200 200

Each cylinder's injection qty mm3/st. 20 17 23

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 113.5 113 114

Basic *

Fixing the lever *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Damper spring setting (3)Rack difference between N = N1 and N = N2
----------
N1=1100r/min N2=900r/min
----------

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=22deg+-5deg b=36deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Drive side
----------

----------
a=54deg+-5deg b=71deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of camshaft's key groove at No 1 cylinder's beginning of injection (3)- (4)-
----------

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

Information:

(1) Crossbar (from 8B7548 Puller).(2) Spacer plate.(3) S1589 Bolt with two 1S379 Washers.(4) 1D4595 Bolt.(5) 3H465 Plate.(6) 1P2403 Dial Indicator.(7) 1P2394 Adapter Plate.(8) 1P2402 Gauge Body.Make reference to Cylinder Liner Projection in Testing and Adjusting for the complete procedure.1. Install gasket and spacer plate (2) with bolts (3) and two 1S379 Washers. Tighten bolts (3) evenly in four steps: 1st step ... 14 N m (10 lb ft)2nd step ... 35 N m (25 lb ft)3rd step ... 70 N m (50 lb ft)4th step ... 95 N m (70 lb ft)2. Install tools as shown. Tighten bolts (4) evenly in four steps: 1st step ... 7 N m (5 lb ft)2nd step ... 20 N m (15 lb ft)3rd step ... 35 N m (25 lb ft)4th step ... 70 N m (50 lb ft)3. Measure cylinder liner projection with dial indicator (6) in 1P2402 Gauge Body (8) as shown. Measure at four places around each cylinder liner near the clamped area. Cylinder liner projection measurements for any cylinder liner must be ... 0.033 to 0.175 mm (.0013 to .0069 in.)Maximum permissible difference between all four measurements ... 0.05 mm (.002 in.)Maximum permissible difference between average projection of any two cylinder liners next to each other ... 0.05 mm (.002 in.)Maximum permissible difference between average projection of all cylinder liners under one cylinder head ... 0.10 mm (.004 in.) If liner projection is not correct, turn the liner to a new position within the bore. If projection can not be corrected this way, move the liner to a different bore. If the projection can not be corrected this way, make reference to Special Instruction, Form No. FMO55228 for complete instructions on the use of 8S3140 Counterboring Tool Arrangement. 4. Minimum permissible depth to machine counterbore to adjust cylinder liner projection ... 0.76 mm (.030 in.) Maximum permissible depth to machine counterbore to adjust cylinder liner protection ... 1.14 mm (.045 in.)Install a 0.76 mm (.030 in.) shim plus any added shims necessary to get the correct cylinder liner projection. Be sure that the 0.76 mm (.030 in.) shim is directly under the cylinder liner flange.