101603-9050 ZEXEL 9 400 615 287 BOSCH INJECTION-PUMP ASSEMBLY 9400615287 1016039050 1671395101

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 287 9400615287

ZEXEL 101603-9050 1016039050

NISSAN-DIESEL 1671395101 1671395101

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Buy INJECTION-PUMP ASSEMBLY 101603-9050 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-9050 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-3470

3. GOVERNOR 105480-0690

4. SUPPLY PUMP 105220-7050

5. AUTOM. ADVANCE MECHANIS 105614-3350

6. COUPLING PLATE 105661-0601

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4620

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 21.6(220)

13. NOZZLE-HOLDER 105048-3330

14. NOZZLE

105017-0530

15. NOZZLE SET

Include in #1:

101472-0100 as _

101603-9050 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 615 287 9400615287

ZEXEL 101603-9050 1016039050

NISSAN-DIESEL 1671395101 1671395101

Zexel num

Bosch num

Firm num

Name

101603-9050

9 400 615 287

1671395101 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
NE603 * 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 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 1-4-2-6- 3-5

Pre-stroke mm 2.75 2.7 2.8

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

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

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

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

Injection quantity adjustment

Adjusting point A

Rack position 12.5

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 79.1 78.1 80.1

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 10.3+-0. 5

Pump speed r/min 285 285 285

Average injection quantity mm3/st. 13 11.2 14.8

Max. variation between cylinders % 0 -10 10

Fixing the rack *

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

Timer adjustment

Pump speed r/min 550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 800

Advance angle deg. 1.5 1 2

Timer adjustment_04

Pump speed r/min 1200

Advance angle deg. 4 3.5 4.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Excess fuel setting for starting: SXL (4)Damper spring setting: DL
----------
RT=1 TH=2.6mm SXL=14.6+0.2mm DL=8.5-0.2mm
----------

Speed control lever angle

F:Full speed M:Minimum-maximum speed (1)Set the pump speed at aa (2)Set the pump speed at bb. (3)Stopper bolt setting
----------
aa=1400r/min bb=900r/min
----------
a=(9deg)+-5deg b=(10deg)+-5deg

0000000901

F:Full load I:Idle S:Stop (1)Set the load lever's stop position so that rack position = aa (and speed = bb).
----------
aa=9.6mm bb=0r/min
----------
a=20deg+-5deg b=21deg+-3deg c=(16deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=20mm
----------
a=71deg+-5deg b=40deg+-5deg

Timing setting

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

----------
a=(40deg)

Information:

preparatory step: a) remove air compressor1. Disconnect the water pump outlet line (1).2. Disconnect the water temperature regulator water bypass line (2).3. Remove the water pump (3).Install Water Pump
1. Position the water pump on the engine.2. Connect the water temperature regulator bypass line.3. Connect water pump outlet line.concluding step: a) install air compressorDisassemble Water Pump
preparatory step: a) remove water pump 1. Remove the water pump cover (1). 2. Loosen the impeller retaining nut flush with the end of the pump shaft. Install tool setup (A) and separate the impeller from the shaft.3. Remove the tool setup and impeller. 4. Remove the bearing cage retaining nuts (3).5. Remove the bearing cage and shaft assembly (2) from the pump housing.6. Remove the ceramic seal and oil seal from the pump housing.7. Remove the bearing retaining nut and spacer from the shaft assembly. 8. Press the gear and bearings from the shaft.Assemble Water Pump
1. Heat the bearings and gear to 300°F (149°C). 2. Install one bearing and its bearing cage (5) on the shaft. Install the gear (4) on the shaft with the concave side towards the bearing cage.3. Install the remaining bearing (3), spacer (2), lock and retaining nut (1). 4. Install the oil seal in the pump housing using tool setup (A). Install the oil seal (8) as shown. 5. Install the ceramic ring (11) and rubber seal (12) in the pump housing with the polished side of the ceramic ring toward the impeller.6. Position the bearing and shaft assembly in the pump housing. Install the bearing cage retaining nuts (7). Lubricate the oil seal lip lightly with SAE 30 engine oil before installing the shaft assembly.7. Install the carbon portion of the seal and the spring on the shaft.8. Install the impeller (10) and retaining nut (6). Tighten the nut to 30 5 lb. ft. (4,1 0,7 mkg) plus the amount required to align on cotter pin hole. Install the cotter pin and bend the legs of the pin around the nut.9. Install the water pump cover (9).concluding step: a) install water pump