101641-9133 ZEXEL 9 400 610 069 BOSCH INJECTION-PUMP ASSEMBLY 9400610069 1016419133 16700c8701

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 069 9400610069

ZEXEL 101641-9133 1016419133

NISSAN-DIESEL 16700C8701 16700c8701

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Service parts 101641-9133 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101064-9040

3. GOVERNOR 105931-1522

4. SUPPLY PUMP 105220-4871

5. AUTOM. ADVANCE MECHANIS 105622-1120

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105141-2130

11. Nozzle and Holder 16600-36W00

12. Open Pre:MPa(Kqf/cm2) 9.8{100}

13. NOZZLE-HOLDER 105071-1271

14. NOZZLE

105000-1740

15. NOZZLE SET

Include in #1:

101641-9133 as INJECTION-PUMP ASSEMBLY

Include in #2:

104740-3700 as _

104740-3703

Cross reference number

BOSCH 9 400 610 069 9400610069

ZEXEL 101641-9133 1016419133

NISSAN-DIESEL 16700C8701 16700c8701

Zexel num

Bosch num

Firm num

Name

101641-9133

9 400 610 069

16700C8701 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
SD33T * K 14BE 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

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 2.3 2.25 2.35

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 -

Rack position 13.7

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 47.8 46.7 48.9

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.9+-0.5

Pump speed r/min 360 360 360

Average injection quantity mm3/st. 7.5 6.4 8.6

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

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

Injection quantity adjustment_03

Adjusting point A

Rack position R1(13.7)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 47.8 46.7 48.9

Basic *

Fixing the lever *

Boost pressure kPa 53.3 53.3

Boost pressure mmHg 400 400

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.7

Pump speed r/min 2000 2000 2000

Average injection quantity mm3/st. 48.7 46.7 50.7

Fixing the lever *

Boost pressure kPa 53.3 53.3

Boost pressure mmHg 400 400

Injection quantity adjustment_05

Adjusting point C

Rack position R2(12.7)

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 35.7 33.7 37.7

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_06

Adjusting point I

Rack position 15.8+-0. 5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 57 57 67

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position R2(12.7)

Boost pressure kPa 15.3 12.6 18

Boost pressure mmHg 115 95 135

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position R1(13.7)

Boost pressure kPa 46.7 40 46.7

Boost pressure mmHg 350 300 350

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 1200

Advance angle deg. 2.2 1.7 2.7

Timer adjustment_04

Pump speed r/min 1900

Advance angle deg. 6 5.5 6.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT (3)Boost compensator stroke: BCL
----------
T1=74 BCL=1+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=37deg+-5deg b=(38deg)+-3deg

Stop lever angle

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

----------
a=10deg+-5deg b=40deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'Y' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=20deg
----------
a=(130deg)

Information:

1W5634 Gear Group
(1) Fuel pump drive gear.(2) Washer. Assemble with large diameter away from gear.(3) Bolt. With the timing pin and timing bolt correctly installed, put a clockwise force of 70 N m (50 lb ft) on the drive gear for the fuel pump and tighten bolt to ... 270 25 N m (200 20 lb ft)(4) Fuel pump idler gear. End play for the idler gear (new) ... 0.10 to 0.41 mm (.004 to .016 in)Maximum permissible end play (worn) ... 0.86 mm (.034 in)Bore in bearing for the idler gear (new) ... 35.004 0.048 mm (1.3781 .0019 in)Diameter of shaft for idler gear (new) ... 34.902 0.020 mm (1.3741 .0008 in)Clearance between shaft and bearing (new) ... 0.033 to 0.168 mm (.0013 to .0066 in)Maximum permissible clearance between shaft and bearing (worn) ... 0.23 mm (.009 in)(5) Plate. Assemble machined side of plate adjacent to the shaft.(6) Bolt. Tighten to ... 25 7 N m (18 5 lb ft)(7) Camshaft gear.(8) Bolts. Tighten to ... 55 7 N m (40 7 lb ft)(9) Crankshaft gear. Maximum temperature of the gear for installation on the crankshaft ... 316°C (600°F)(10) Idler gear for oil pump.(11) Drive gear for oil pump.2P9642 Gear Group
(1) Fuel pump drive gear.(2) Washer. Assemble with large diameter away from gear.(3) Bolt. With the timing pin and timing bolt correctly installed, put a clockwise force of 70 N m (50 lb ft) on the drive gear for the fuel pump and tighten bolt to ... 149 7 N m (110 5 lb ft)(4) Fuel pump idler gear. End play for the idler gear (new) ... 0.10 to 0.41 mm (.004 to .016 in)Maximum permissible end play (worn) ... 0.86 mm (.034 in)Bore in bearing for the idler gear (new) ... 35.004 0.048 mm (1.3781 .0019 in)Diameter of shaft for idler gear (new) ... 34.902 0.020 mm (1.3741 .0008 in)Clearance between shaft and bearing (new) ... 0.033 to 0.168 mm (.0013 to .0066 in)Maximum permissible clearance between shaft and bearing (worn) ... 0.23 mm (.009 in)(5) Plate. Assemble machined side of plate adjacent to the shaft.(6) Bolt. Tighten to ... 25 7 N m (18 5 lb ft)(7) Camshaft gear.(8) Bolts. Tighten to ... 55 7 N m (40 7 lb ft)(9) Crankshaft gear. Maximum temperature of the gear for installation on the crankshaft ... 316°C (600°F)(10) Idler gear for oil pump.(11) Drive gear for oil pump.