101606-9840 ZEXEL 9 400 615 582 BOSCH INJECTION-PUMP ASSEMBLY 9400615582 1016069840

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 582 9400615582

ZEXEL 101606-9840 1016069840

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Buy INJECTION-PUMP ASSEMBLY 101606-9840 zexel genuine, new aftermarket engine parts with delivery

Service parts 101606-9840 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9090

3. GOVERNOR 105412-2250

4. SUPPLY PUMP 105210-4700

5. AUTOM. ADVANCE MECHANIS 105643-0870

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6780

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105031-3900

14. NOZZLE

105015-6440

15. NOZZLE SET

Include in #1:

101402-7241 as _

101606-9840 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 615 582 9400615582

ZEXEL 101606-9840 1016069840

Zexel num

Bosch num

Firm num

Name

101606-9840

9 400 615 582

HYUNDAI

INJECTION-PUMP ASSEMBLY
6D16 * 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 131424-5520

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 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 3.3 3.25 3.35

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 B

Rack position 10.5

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 59.5 58.5 60.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 8.8+-0.5

Pump speed r/min 285 285 285

Average injection quantity mm3/st. 10 8.5 11.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 71 61 81

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1200++

Advance angle deg. 0 0 0

Remarks
Do not advance until starting N = 1200.

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 1.5 1.5 1.5

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)Supplied with torque spring not set. (4)RACK LIMIT (5)Rack difference between N = N1 and N = N2
----------
K=5 N1=1200r/min N2=750r/min
----------

Speed control lever angle

F:Full speed I:Idle S:Stop
----------

----------
a=3deg+-5deg b=18deg+-5deg c=35deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=2.5deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of timer's tooth at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=18deg
----------
a=(2deg)

Information:

To prevent possible personal injury, do not disconnect any air lines from the air compressor until the air pressure in the system has been released.
1. Release the pressure in the air system. 2. Disconnect tube assembly (3) from the air compressor.3. Disconnect tube assembly (4) from the air compressor.4. Disconnect the two hose assemblies from locations (6) on the power steering pump.5. Disconnect the tube assembly at air inlet port (8).6. Disconnect the tube assembly at air outlet port (9).7. Disconnect the clip and hose assembly (7) at the air compressor.8. Remove two bolts (2) and the washers that hold the air compressor to the cylinder block.9. Fasten a lifting strap and a hoist to air compressor (1).10. Remove two bolts (5) and the washers that hold the air compressor to the front housing. Remove the air compressor and gasket from the front housing. The weight of the air compressor is 26 kg (57 lb).11. Remove the nut and washer that hold the drive gear to the air compressor. Remove the drive gear. The following steps are for the installation of the air compressor.12. Check the condition of the gasket used between the air compressor and front housing. If the gasket is damaged, use a new part for replacement.13. Put the drive gear in position on the air compressor, and install the washer and nut that hold it. Tighten the nut to a torque of 160 15 N m (120 11 lb ft).14. Put the gasket in position on the air compressor. Fasten a lifting strap and a hoist to air compressor (1). Put the compressor in position in the front housing. Install two bolts (5) and the washers that hold the compressor to the front housing.15. Install two bolts (2) and the washers that hold the air compressor to the cylinder block. First, tighten the bolts finger tight; then tighten the bolts to a torque of 55 10 N m (41 7 lb ft).16. Connect hose assembly (7) to the air compressor. Connect the clip that holds the hose assembly to the air compressor. Tighten the bolt that holds the clip to a torque of 40 8 N m (30 6 lb ft).17. Connect the tube assembly to air outlet port (9).18. Connect the tube assembly to air inlet port (8).19. Connect the two hose assemblies at locations (6) on the power steering pump.20. Connect tube assemblies (3) and (4) to the air compressor.