101608-6480 ZEXEL 9 400 619 515 BOSCH INJECTION-PUMP ASSEMBLY 9400619515 1016086480

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 619 515 9400619515

ZEXEL 101608-6480 1016086480

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Buy INJECTION-PUMP ASSEMBLY 101608-6480 zexel genuine, new aftermarket engine parts with delivery

Service parts 101608-6480 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6730

3. GOVERNOR 105411-2550

4. SUPPLY PUMP 105210-5450

5. AUTOM. ADVANCE MECHANIS 105680-9050

6. COUPLING PLATE 105663-1150

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-5340

11. Nozzle and Holder ME441452

12. Open Pre:MPa(Kqf/cm2) 17.7{180}

13. NOZZLE-HOLDER 105030-3660

14. NOZZLE 105025-4020

15. NOZZLE SET

Include in #1:

101608-6480 as INJECTION-PUMP ASSEMBLY

Include in #2:

104740-0624 as _

Cross reference number

BOSCH 9 400 619 515 9400619515

ZEXEL 101608-6480 1016086480

Zexel num

Bosch num

Firm num

Name

101608-6480
101608-6481

9 400 619 515

INJECTION-PUMP ASSEMBLY
* 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 255 255 255

Overflow valve opening pressure kgf/cm2 2.6 2.6 2.6

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)
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 4.5 4.45 4.55

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 A

Rack position 11.5

Pump speed r/min 895 895 895

Average injection quantity mm3/st. 122.5 121.5 123.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 48.7 48.7

Boost pressure mmHg 365 365

Injection quantity adjustment_02

Adjusting point -

Rack position 8.5+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 16.5 15 18

Max. variation between cylinders % 0 -15 15

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 11.9++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 100 100 110

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position R1-1.45

Boost pressure kPa 13.3 10.6 16

Boost pressure mmHg 100 80 120

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R1(11.5)

Boost pressure kPa 35.3 28.6 42

Boost pressure mmHg 265 215 315

Timer adjustment

Pump speed r/min 830--

Advance angle deg. 0 0 0

Load 4/4

Remarks
Start

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 3 2.5 3.5

Load 0/4

Remarks
Measure speed (beginning of operation).

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 0 0 0

Load 0/4

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 780

Advance angle deg. 0.5

Load 4/4

Timer adjustment_05

Pump speed r/min 895

Advance angle deg. 0.75 0.25 1.25

Load 4/4

Timer adjustment_06

Pump speed r/min -

Advance angle deg. 1.5 1 2

Load 4/4

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)RACK LIMIT (4)Boost compensator stroke: BCL (5)Set idle sub-spring
----------
K=5 BCL=1.45+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Set the pump speed at aa (2)When pump speed set at bb (3)Stopper bolt setting
----------
aa=905r/min bb=760r/min
----------
a=20deg+-5deg b=8deg+-5deg c=5deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal (2)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.5mm
----------
a=35deg+-5deg b=(55deg)

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=6deg
----------
a=(3deg)

Information:

Overview of Radiator-Equipped Engine's Cooling System
Flow of coolantWater Pump
Removal and Inspection
Removal sequence and points to check on water pump(1) Cooling fan(2) Fan spacer(3) Water pump pulley(4) Fan belt(5) Water bypass hose(6) Water pump assembly Key Points for RemovalRemoval of the water pump pulley and fa belt is possible after loosening slightly both the adjusting bolt (1) and support bolt (2). This allows the alternator to be moved and then the V-belt slackened.
Removing water pump pulley Key Points for InspectionTurn the pump by hand to check the impeller shaft for smooth and quiet rotation. If irregular or noisy rotation is detected, replace them as an assembly.
Inspecting impeller and shaft rotationInstallation
Perform installation by following the removal sequence in reverse: Key Points for Inspection(1) Install the six water pump mounting bolts in their correct locations by referring to the figure on the right for the nominal diameters and lengths from bottom of head.
Correct locations of water pump mounting bolts(2) Use a new gasket when installing the water pump.(3) Adjust the fan belt tension according to the following specification.Unit: mm (in.)
Fan belt tension adjustmentThermostat
Disassembly
Removal sequence and points to check on the thermostat(1) Water hose(2) Water outlet fitting(3) Thermostat(4) Thermostat fitting(5) Thermo switchInspection
Key Points for Removal(1) Operation Test of Thermostat
Put the thermostat in a container of water. Heat the water and record both of the temperatures at which the valve starts to open and at which the valve lift reaches 8 mm (0.3 in.). If the readings do not conform to the specification below, replace the thermostat.
Operation test of thermostat
Carry out this operation with extreme care to avoid burns and prevent fire.
Installation
Except that the instructions shown below are to be followed, perform installation by following the removal sequence in reverse: Key Points for Inspection(1) Thermo Switch
Apply sealant to the threads an tighten to the specified torque.
Installing thermo switch(1) Thermostat
Make sure that the thermostat flange fits correctly into the counterbore in the thermostat fitting.
Installing thermostat