101602-9250 ZEXEL 9 400 612 996 BOSCH INJECTION-PUMP ASSEMBLY 9400612996 1016029250

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 612 996 9400612996

ZEXEL 101602-9250 1016029250

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Buy INJECTION-PUMP ASSEMBLY 101602-9250 zexel genuine, new aftermarket engine parts with delivery

Service parts 101602-9250 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-9010

3. GOVERNOR 105492-0090

4. SUPPLY PUMP 105210-3210

5. AUTOM. ADVANCE MECHANIS 105642-0020

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105151-4120

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 17.2{175}

13. NOZZLE-HOLDER 105081-4050

14. NOZZLE 105015-3720

15. NOZZLE SET

Include in #1:

101492-0461 as _

101602-9250 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 996 9400612996

ZEXEL 101602-9250 1016029250

Zexel num

Bosch num

Firm num

Name

101602-9250

9 400 612 996

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 12.2

Pump speed r/min 800 800 800

Each cylinder's injection qty mm3/st. 115.5 114 117

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point B

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 *

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)Set minimum speed. (3)Rack difference between N = N1 and N = N2 (4)Damper spring setting: DL
----------
N1=1100r/min N2=800r/min DL=4.6+-0.5mm
----------

Speed control lever angle

F:Full speed M:Minimum-maximum speed (1)Stopper bolt setting (2)Stopper bolt setting
----------

----------
a=44.5deg+-5deg b=12deg+-5deg

0000000901

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

----------
a=28deg+-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. Remove the fuel injection lines. It is not necessary to remove the fuel transfer pump, the fuel injection pump housing and governor to remove the fuel injection pumps. 2. Remove cover (1). 3. Move the rack until tool (A) can be installed to hold the rack in the center position. The rack must be in the center position to remove the fuel injection pumps.4. Use tool (B) to remove bushing (2). 5. Install tool (C) on the bonnet and remove the fuel injection pump. 6. Remove spacer (3) from the fuel injection pump housing. Spacers (3) are the same thickness for each fuel injection pump so they can be mixed. The fuel injection pump plungers and barrels are sets and can not be mixed.Install Fuel Injection Pumps
1. Install spacer (1) in the fuel injection pump housing. 2. Move the rack until tool (A) can be installed to hold the rack in the center position. The rack must be in the center position to install the fuel injection pumps.3. Turn the camshaft until the lobe of the camshaft is down for the pump to be installed. 4. Install tool (B) on the bonnet of the fuel injection pump. Put clean oil on O-ring seal (4) and install the O-ring seal and bushing (5) over tool (B) as shown. 5. Install the fuel injection pump in the pump housing with saw cut (slot) (3) in the gear in alignment with small pin (2) in the lifter assembly and groove (7) in the barrel in alignment with large pin (6) in the pump housing.6. Push down on tool (B) and tighten bushing (5) by hand until the bushing is even with the top of the housing. If installation of the bushing can not be made this far by hand, remove it. Remove the pump, put the parts in alignment again and install the bushing again.
If installation of pump is correct, the bushing can be tightened by hand until it is even with the face of the pump housing.
7. Remove tool (B) and install tool (C) in the bushing. Use tool (C) and a torque wrench to tighten the bushing to a torque of 165 14 N m (120 10 lb. ft.).8. Remove tools (C) and (A). Install the cover on the fuel injection pump housing.9. Install the fuel injection lines. Tighten the fuel injection line nuts to a torque of 41 7 N m (30 5 lb.ft.).Disassemble Fuel Injection Pumps
start by:a) remove fuel injection pumps
Be careful when the injection pumps are disassembled. Do not damage the surfaces of the plungers, barrels and bonnets. Any scratches will cause leakage inside the fuel injection pump. The plunger and barrel for each pump are made as a set. Do not put the plunger of one pump in the barrel of another pump. If one part has wear, install a complete new pump assembly. Be careful when the plunger is put into the bore of the barrel.
1. Pull plunger (1)