101603-2631 ZEXEL 9 400 611 698 BOSCH INJECTION-PUMP ASSEMBLY 9400611698 1016032631

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 611 698 9400611698

ZEXEL 101603-2631 1016032631

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Buy INJECTION-PUMP ASSEMBLY 101603-2631 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-2631 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-5310

3. GOVERNOR 105401-0861

4. SUPPLY PUMP 105210-5560

5. AUTOM. ADVANCE MECHANIS 105672-0560

6. COUPLING PLATE 105662-1160

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4100

11. Nozzle and Holder 23600-2710A

12. Open Pre:MPa(Kqf/cm2) 17.7{180}

13. NOZZLE-HOLDER 105030-4440

14. NOZZLE 105015-9220

15. NOZZLE SET

Include in #1:

101603-2631 as INJECTION-PUMP ASSEMBLY

Include in #2:

104749-6830 as _

Cross reference number

BOSCH 9 400 611 698 9400611698

ZEXEL 101603-2631 1016032631

Zexel num

Bosch num

Firm num

Name

101603-2631
101603-2632

9 400 611 698

INJECTION-PUMP ASSEMBLY
* 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 134424-0920

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

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 1-4-2-6- 3-5

Pre-stroke mm 4.8 4.77 4.83

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point A

Rack position 11.8

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 121.5 119.5 123.5

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Boost pressure kPa 37.3 37.3

Boost pressure mmHg 280 280

Injection quantity adjustment_02

Adjusting point -

Rack position 6.2+-0.5

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 10 9 11

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

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

Boost compensator adjustment

Pump speed r/min 800 800 800

Rack position R1-0.7

Boost pressure kPa 10.7 10.7 12

Boost pressure mmHg 80 80 90

Boost compensator adjustment_02

Pump speed r/min 800 800 800

Rack position R1(11.8)

Boost pressure kPa 24 24 24

Boost pressure mmHg 180 180 180

Timer adjustment

Pump speed r/min -

Advance angle deg. 0 0 0

Remarks
Measure speed (beginning of operation).

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 1.5 1.2 1.8

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)SMA RACK LIMIT; RAL (boost pressure exceeds P1 at N = N1) (4)Boost compensator stroke (5)Set idle sub-spring (6)Main spring setting (7)Perform governor adjustment at an ambient temperature of at least 15 deg C (rack limit spring is shape memory alloy).
----------
K=13 RAL=13.1+-0.1mm N1=350r/min P1=37.3kPa(280mmHg)
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Speed control lever angle

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

----------
a=16deg+-5deg b=24deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery) (2)Normal stop (3)Stopper bolt setting (4)Stopper bolt setting (5)Use the hole above R = cc
----------
aa=0r/min bb=1-0.5mm cc=25mm
----------
a=13deg+-5deg b=50deg+-5deg

Timing setting

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

----------
a=(50deg)

Information:

1. Drain the coolant from the cooling system to a level below that of the water pump.2. Remove elbow (1).3. Remove bolts (4) that hold cover (2) to the water pump. Remove bolts (5) that hold elbow (3) to cover (2).4. Remove line (6).5. Remove cover (2). Remove elbow (3). 6. Remove four bolts (7).7. Remove nuts (8) and one bolt (not shown). Remove water pump.Install Water Pump
1. Put the water pump in position on the timing gear cover. Install nuts (8) and one bolt that hold the pump to the timing gear cover.2. Install four bolts (7). 3. Put clean engine oil or glycerin on O-ring seals (9). Install elbow (3). 4. Put cover (2) in position on the water pump. Install bolts (4) that hold the cover to the water pump and bolts (5) that hold elbow (3) to the cover.5. Install elbow (1).6. Install line (6).7. Fill the cooling system to the proper level. See the Operation & Maintenance Manual.Disassemble Water Pump
Start By:a. remove water pump 1. Remove O-ring seal (1) from adapter (2).2. Remove adapter (2) with a screwdriver. Remove the seal from the edge of adapter (2).3. Remove bolt (3) and washer. 4. Remove impeller (4) from the water pump housing with Tooling (A). 5. Remove seal assembly (5). Remove ring and seal (6). 6. Remove the bolt and washer that hold gear (7) on the water pump shaft.7. Remove gear (7) with Tooling (B).8. Remove bolts and retainer (9).9. Remove O-ring seal (8). 10. Remove shaft (10) and bearings as a unit.11. Remove bearing (11), spacer (12) and bearing (13) from shaft (10).12. Remove lip-type seal from the gear side of the water pump. Remove ring and seal from the impeller side of the water pump.Assemble Water Pump
1. Put clean engine oil or glycerin on the lip of seal (1). Install seal (1) as shown with Tooling (A). 2. Install bearing (4), spacer (3) and bearing (5) on shaft (2). Install shaft (2) in the pump housing. 3. Install retainer (7) and O-ring seal (8).4. Install gear (6). Install washer and bolt that hold gear (6) to shaft (2).
Clean water only is permitted for use as a lubricant for assistance at installation. Do not damage or put hands on the wear surface of the carbon ring or the ceramic ring. Install the ceramic ring with the smoothest face of the ring toward the carbon seal assembly.
5. Put ceramic ring (10) in position in the rubber seal (9). Use hand pressure and Tool (11) (which is with the replacement ring) to install the ceramic ring in the housing. 6. Remove the spring from seal assembly (12). Use hand pressure and Tool (11) (which is with the replacement ring) to install the seal assembly. Push seal assembly on the shaft until the seal faces make light contact. 7. Install spring (13) on the seal assembly and impeller (14) on the shaft. Install the bolt and washer on the shaft. Tighten the bolt to a