101607-9890 ZEXEL 9 400 610 738 BOSCH INJECTION-PUMP ASSEMBLY 9400610738 1016079890 16700z5767

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 738 9400610738

ZEXEL 101607-9890 1016079890

NISSAN-DIESEL 16700Z5767 16700z5767

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Service parts 101607-9890 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-3510

3. GOVERNOR 105462-7520

4. SUPPLY PUMP 105220-7050

5. AUTOM. ADVANCE MECHANIS 105672-0570

6. COUPLING PLATE 105661-1150

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6690

11. Nozzle and Holder 16600-Z5519

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

13. NOZZLE-HOLDER 105031-4650

14. NOZZLE

105015-6380

15. NOZZLE SET

Include in #1:

101607-9890 as INJECTION-PUMP ASSEMBLY

Include in #2:

104746-5434 as _

Cross reference number

BOSCH 9 400 610 738 9400610738

ZEXEL 101607-9890 1016079890

NISSAN-DIESEL 16700Z5767 16700z5767

Zexel num

Bosch num

Firm num

Name

101607-9890

9 400 610 738

16700Z5767 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
FE6B 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 131424-1520

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 3.4 3.35 3.45

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 9.8

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 58.9 57.9 59.9

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position R1(10)

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 80.6 79.6 81.6

Max. variation between cylinders % 0 -5 5

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 7.9+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 8.3 6.5 10.1

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Injection quantity adjustment_04

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 80 80

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 850--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 800

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1500

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)Tolerance for racks not indicated: +-0.05mm. (4)Excess fuel setting for starting: SXL (N = N1) (5)Damper spring setting
----------
RT=1 TH=1.8mm SXL=R1+0.2mm N1=500r/min
----------

0000000901

F:Full load I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=70mm
----------
a=18deg+-5deg b=19.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa (2)Drive side
----------
aa=20mm
----------
a=40deg+-5deg b=71deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(60deg)

Information:

Introduction
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.If the crankshaft, gear case and/or crank gear are replaced, it is necessary to perform the injection timing correction procedure. The following steps show how to calculate/determine the new injection timing by measuring angular deviation between the crankshaft TDC and Crank Position sensor detected TDC.Note: Once complete the engine ecm must be reprogrammed with the new injection timing value. Follow all Steps below.Procedure
Illustration 1 g06220080
(1) TC Mark (Flywheel Housing)
(2) TC Mark (Flywheel)
Remove valve cover, injector, and rocker arm. Bring the piston of cylinder 4 to TDC.
Illustration 2 g06220082
(3) Dial Gauge
(4) Valve
(5) O-ring
Remove the #4 exhaust valve bridge arm and valve spring. Insert a small O-ring (5) so the valve (4) does not fall into the cylinder.
Set the dial gauge (3) on the tip of the valve (4).
Illustration 3 g06220083
(6) Tri-sqaure
(7) Flywheel Housing
(8) Flywheel
Illustration 4 g06220087
(7) Flywheel Housing
(8) Flywheel
(9) Reference Line
Turn the flywheel counterclockwise and measure the position where the tip of the valve is highest.
Stop the flywheel at the position where the tip of the valve is the highest. Put a tri-sqaure (6) on the flywheel housing (7) and the flywheel (8) and draw a reference line (9).Do not drop the valve (4) into the cylinder. When measuring the highest position of the tip of the valve do not rotate the flywheel clockwise. If you go past the highest point of the valve, back up the flywheel slightly and measure the highest point of the valve. The reference line (9) indicates the TDC of the crankshaft.
Illustration 5 g06220092
(10) Tester
(11) Crankshaft Position Sensor
Illustration 6 g06220095
(11) Crankshaft Position Sensor
(12) Ground Terminal
(13) Output Terminal
Connect the engine harness and the main switch. Connect battery.Attach the tester (10) to the output terminal (13) and the ground terminal (12) of the crankshaft position sensor (11). Turn the main switch "ON". Turn the flywheel and make sure that the voltage of the crankshaft position sensor goes from 0→ 5 V or 5 → 0 V.
Illustration 7 g06220100
(14) Pulsar Gear
(15) 14th Tooth
(16) Missing Teeth
Rotate the flywheel and align the crankshaft position sensor to the part of the pulsar gear (14) that is missing teeth (16). The 14th tooth (15) from the missing teeth is the standard. Slowly turn the flywheel counterclockwise and stop the flywheel at the point where the needle of the tester changes momentarily from 0→ 5 V, the 14th tooth. That point is where the crankshaft position sensor detects TDC.
Illustration 8 g06220101
(17) Crankshaft TDC
(18) Detection Point of Crankshaft Position Sensor TDC
Illustration 9 g06220104
(19) Interval
Set the tri-square (6) on the reference line (9) on the flywheel housing side and mark the detection point of the crankshaft position sensor TDC (18) on the flywheel.
Measure the interval (19) between the crankshaft TDC (17) and the detection point of the crankshaft position sensor TDC (18).
Calculation of the fuel injection timing correction 1 mm (0.039 inch): 0.342°.Corrected angle = 0.342° X actual interval.
Overwrite the injection timing correction value on the engine ecm registration website refer to REHS9707, "Registering