101603-8662 ZEXEL 9 400 613 140 BOSCH INJECTION-PUMP ASSEMBLY 9400613140 1016038662 8943959803

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 140 9400613140

ZEXEL 101603-8662 1016038662

ISUZU 8943959803 8943959803

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Buy INJECTION-PUMP ASSEMBLY 101603-8662 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-8662 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6310

3. GOVERNOR 105932-1141

4. SUPPLY PUMP 105210-6090

5. AUTOM. ADVANCE MECHANIS 105643-1140

6. COUPLING PLATE 105661-1140

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4531

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105030-4700

14. NOZZLE 105025-1000

15. NOZZLE SET

Include in #1:

101492-0511 as _

101492-0512

101603-8662 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 613 140 9400613140

ZEXEL 101603-8662 1016038662

ISUZU 8943959803 8943959803

Zexel num

Bosch num

Firm num

Name

101603-8662
101603-8663

9 400 613 140

8943959803 ISUZU

INJECTION-PUMP ASSEMBLY
6HH1-S * K 14BF PE6AD 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 131424-4920

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-5-3-6- 2-4

Pre-stroke mm 4.7 4.65 4.75

Rack position
After adjusting injection quantity. R=A

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 12.6

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 82 80.4 83.6

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 275 275 275

Average injection quantity mm3/st. 8.5 7.2 9.8

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(12.6)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 82 81 83

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1

Pump speed r/min 1425 1425 1425

Average injection quantity mm3/st. 88.5 85.3 91.7

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.2

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 72.5 69.3 75.7

Fixing the lever *

Timer adjustment

Pump speed r/min 1300--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1250

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1400

Advance angle deg. 4.5 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.
----------
T1=K49
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=35mm
----------
a=14deg+-5deg b=40deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=46.5mm
----------
a=34.5deg+-5deg b=40deg+-5deg

0000001501 I/P WITH LOAD PLUNGER ADJ

Plunger assembly number: PL (stamping: ST) 1. Adjustment procedures (1)Insert the pre-stroke adjusting shims L1 for each cylinder. (2)Adjust injection quantity.(max. var. bet. cyl. idling a1, full a2) (3)At basic point A, adjust so that the pre-stroke is L2. (4)Reconfirm the injection quantity.
----------
PL=131153-9020 ST=A769 L1=1mm L2=4.7+-0.05mm a1=+-14% a2=+-2.5%
----------

0000001601 AIR CYLINDER

1. (1) Set the speed lever to idle. (2)Screw in air cylinder (A) (3)Set the clearance from the speed lever (B) at approximately L.
----------
L=1mm
----------

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)At rack position = bb
----------
aa=6deg bb=12.6mm
----------
a=(150deg)

Information:

start by: a) remove oil pump1. Check the main bearing caps for identification for their location and direction in the block. The caps must be installed in the same location and direction from which they were removed. 2. Remove No. 2 through No. 6 bearing caps (1). Remove thrust plates from No. 4 main bearing. 3. Remove the upper halves of main bearings by putting tool (A) in oil (2) in the crankshaft. Turn the crankshaft in the direction which will push the end of the bearing with a tab out first.
If the crankshaft is turned in the wrong direction, the tab of the bearing will be pushed between the crankshaft and cylinder block. This can cause damage to either or both.
4. Remove the lower halves of the bearings from the caps. Install the bearings dry when the clearance checks are made. Put clean engine oil on the bearings for final assembly.5. Install new bearings in the caps.6. Install the upper halves of the bearings in the cylinder block with tool (A). Be sure tabs (3) on the back of the bearings fit in the grooves of the caps and cylinder block.7. Check the bearing clearance with Plastigage (B). Put Platigage (B) on the bearings. Do not turn the crankshaft when Plastigage (B) is in position.
Be sure the main bearing caps are installed so the numbers on the side of the cylinder block are the same as the numbers on the bearing caps, and the arrows (4) on the bearing caps are toward the front of the cylinder block.
When the bearing clearance is checked and the engine is in a vertical position, such as in the vehicle, the crankshaft will have to be lifted up with a force equal to the weight of the crankshaft and held against the upper halves of the main bearings to get a correct measurement with Plastigage (B). The Plastigage will not hold the weight of the crankshaft and give a correct indication. If the engine is in a horizontal position, such as on an engine stand, it is not necessary to hold the crankshaft up. Do not turn crankshaft when Plastigage is in position to check clearance.
Do not use an impact wrench to tighten the bolts the additional 120° 5°.
8. Install the bearing caps for No. 2 through No. 6 main bearings. Put clean engine oil on the bolts. Install the bolts and tighten bolts, at end, with tab first, to a torque of 190 10 lb. ft. (260 14 N m). Turn the bolts an extra 120° 5° first at the end opposite of the tab. Remove the bearing caps for No. 2 through No. 6 main bearings. Remove Plastigage (B) from the caps. Check the thickness of Plastigage (B) to find the bearing clearance. The bearing clearance must be .0036 to .0073 in. (0.091 to 0.185 mm) with new bearings. Maximum clearance with used bearings is .010 in. (0.25 mm).9. Put clean engine oil on the