101605-0330 ZEXEL 9 400 613 436 BOSCH INJECTION-PUMP ASSEMBLY 9400613436 1016050330 1156034980

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 436 9400613436

ZEXEL 101605-0330 1016050330

ISUZU 1156034980 1156034980

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Buy INJECTION-PUMP ASSEMBLY 101605-0330 zexel genuine, new aftermarket engine parts with delivery

Service parts 101605-0330 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101062-8410

3. GOVERNOR 105411-2710

4. SUPPLY PUMP

105220-7230

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156643-1720

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-8341

11. Nozzle and Holder 1-15300-432-1

12. Open Pre:MPa(Kqf/cm2) 16.7{170}/19.6{200}

13. NOZZLE-HOLDER 105041-4410

14. NOZZLE

15. NOZZLE SET 105019-2900

Include in #1:

101402-4270 as _

101605-0330 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 613 436 9400613436

ZEXEL 101605-0330 1016050330

ISUZU 1156034980 1156034980

Zexel num

Bosch num

Firm num

Name

101605-0330
101605-0331

9 400 613 436

1156034980 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1-T * 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 134424-4120

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

Tester oil delivery pressure kPa 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 4.2 4.15 4.25

Beginning of injection position
Drive 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 A

Rack position 9.6

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 82.5 81 84

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 71.3 71.3

Boost pressure mmHg 535 535

Injection quantity adjustment_02

Adjusting point -

Rack position 7.7+-0.5

Pump speed r/min 410 410 410

Average injection quantity mm3/st. 12 10.7 13.3

Max. variation between cylinders % 0 -14 14

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.

Injection quantity adjustment_03

Adjusting point E

Rack position 9.8++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 80 75 85

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 550 550 550

Rack position R1-0.4

Boost pressure kPa 31.3 27.3 35.3

Boost pressure mmHg 235 205 265

Boost compensator adjustment_02

Pump speed r/min 550 550 550

Rack position R1(9.6)

Boost pressure kPa 58 51.3 64.7

Boost pressure mmHg 435 385 485

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)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting (6)Boost compensator stroke: BCL
----------
K=17 BCL=0.4+-0.1mm
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Speed control lever angle

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

----------
a=13deg+-5deg b=21deg+-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
----------
aa=0r/min bb=1-0.5mm
----------
a=32deg+-5deg b=(55deg)

0000001501 TAMPER PROOF

Tamperproofing-equipped boost compensator cover installation procedure (A): After adjusting the boost compensator, assemble then tighten the bolts to remove the heads. (B): Specified torque (1)Before adjusting the governor and the boost compensator, tighten the screw to the specified torque. (Tightening torque T = T1 maximum) (2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T2)
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
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Timing setting

(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=8deg
----------
a=(100deg)

Information:

Start By:a. remove cylinder headb. remove oil panc. remove oil pumpd. remove cooling tubes 1. Check the connecting rods and caps for their identification and location.2. Remove rod cap nuts (1) and cap (2) from connecting rod (3). Remove the lower half of bearing (4) from cap (2).
To protect the crankshaft from the threaded portion of connecting rod bolts (5), cut a short piece of rubber hose and install it over both rod bolts (5).
3. Remove the piston and connecting rod, then remove the upper half of rod bearing (4). The following steps are for the installation of the pistons and connecting rod assemblies.4. Put clean oil on piston rings, connecting rod bearings and cylinder bore.5. Position the piston ring end gaps 120° apart and install tooling (A).6. Put the short pieces of hose over the threaded portion of rod bolts (5), to protect crankshaft.7. With number one crankshaft throw at bottom center, install the piston and connecting rod. Engines which use one piece pistons have the word "FRONT" stamped on the crown of the piston. Make sure the word "FRONT" is toward the front of the engine when the piston is installed.8. Taking care to line up connecting rod and crankshaft, carefully tap piston into cylinder bore until tooling (A) comes off the piston. 9. Before connecting rod (3) comes in contact with the crankshaft, install upper half of rod bearing (4). Be sure the bearing tab engages the groove in the connecting rod.10. Put engine oil on upper rod bearing surface, then tap piston down, guiding connecting rod onto crankshaft.11. Position lower half of rod bearing (4) in corresponding numbered rod cap (2). Be sure the bearing tab engages the grove in the rod caps.12. Put engine oil on the lower rod bearing surface, then install the rod cap. Install the bearing cap on the connecting rod with the number on the bearing (rod) cap on the same side and same number as on the connecting rod.13. Put engine oil on the threads of bolts (5). Install rod cap nuts (1) and tighten them to a torque of 54 7 N m (40 5 lb.ft.).14. Put an alignment mark on cap and nut. Then, tighten each nut an additional 60° 5° (1/6 turn).15. Repeat the steps for the remainder of the pistons and connecting rods.End By:a. install cooling tubesb. install oil pumpc. install oil pand. install cylinder headDisassemble And Assemble Pistons And Connecting Rods
Start By:a. remove pistons and connecting rods 1. Remove snap ring (1) remove piston pin (2). Separate piston (3) and connecting rod (4).
One Piece Piston
Two Piece Piston2. Use tooling (A) and remove piston rings (5). The following steps are for the assembly of the pistons and connecting rods.3. Check the clearance between the ends of the piston rings (5). See the topic, Pistons And Rings in the Specifications section of the service manual. The oil ring is to be installed over the spring with the end gap 180° from the