103682-0540 ZEXEL 9 400 611 758 BOSCH INJECTION-PUMP ASSEMBLY 9400611758 1036820540

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 611 758 9400611758

ZEXEL 103682-0540 1036820540

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Service parts 103682-0540 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 103068-1200

3. GOVERNOR 105445-1050

4. SUPPLY PUMP 105235-1870

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-0490

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105111-4950

11. Nozzle and Holder 6162-13-8100

12. Open Pre:MPa(Kqf/cm2) 31.4{320}

13. NOZZLE-HOLDER 105041-7101

14. NOZZLE 105025-3020

15. NOZZLE SET

Include in #1:

103682-0540 as INJECTION-PUMP ASSEMBLY

106873-2934 as _

Cross reference number

BOSCH 9 400 611 758 9400611758

ZEXEL 103682-0540 1036820540

Zexel num

Bosch num

Firm num

Name

103682-0540
103682-0541

9 400 611 758

INJECTION-PUMP ASSEMBLY
6M170A * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8130

Bosch type code EFEP215A

Nozzle 105780-0050

Bosch type code DN6TD119NP1T

Nozzle holder 105780-2090

Bosch type code EFEP215

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-4-1500

Overflow valve 131425-1620

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 4.5 4.45 4.55

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 20.5

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 701 695 707

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Boost pressure kPa 92 92

Boost pressure mmHg 690 690

Injection quantity adjustment_02

Adjusting point B

Rack position 9.7+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 56.5 50.5 62.5

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point C

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 555 545 565

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 R1-4.4

Boost pressure kPa 24 21.3 26.7

Boost pressure mmHg 180 160 200

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R1(20.5)

Boost pressure kPa 78.6 71.9 85.3

Boost pressure mmHg 590 540 640

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
----------
K=14 BCL=4.4+-0.1mm
----------

Speed control lever angle

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

----------
a=14deg+-5deg b=32deg+-3deg c=32deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Clearance between stopper bolt and lever must be aa. (2)Use the hole at R = bb (3)No return spring
----------
aa=2+1mm bb=40mm
----------
a=16deg+-5deg b=40deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(70deg)

Information:

Illustration 4 g01621593
(4) The process of crimping has been improved in the location that is shown. The Fifth Improvement
The length of the bolts that secure the fuel transfer pump to the HEUI pump body have increased. The torques on the bolts that secure the transfer pump to the HEUI pump body have also increased in order to improve durability.
HEUI pumps that have been returned from the field have been inspected and broken bolts that connect the fuel transfer pump to the main HEUI pump were found.
The major symptom that is related to this issue is an oil leak between the fuel transfer pump and the HEUI pump.
The bolts that make this connection were lengthened as well as the torques were increased in order to provide a better connection.
This improvement was effective with the following part numbers: 319-0607, 319-0674, 319-0675, 319-0676, 319-0677, 319-0678, 319-0622, 319-0610 and 319-0680
Illustration 5 g01621594
(5) Location of the three bolts that have been lengthened and increased torques have been applied. Note: The applications that utilize an electric fuel transfer pump also have this improvement for the cover that goes in place of the mechanical fuel transfer pump.Note: Refer to Special Instruction , REHS3830 for the following items: parts information, installation of parts and torque procedures that are related to this improvement.All current remanufactured part numbers are being built with the latest improvements. A list of all the current new part numbers and the part numbers of the remanufactured equivalent can be seen below.
Table 1
Current New Part Numbers Remanufactured Equivalent
319-0607 -
319-0674 -
319-0675 10R7145
319-0676 10R7146
319-0677 10R7147
319-0678 10R7148
319-0622 -
319-0610 10R3044
319-0680 - Note: All part numbers that are referenced in this publication were current on 15 July 2008. Part numbers are subject to a change.
Table 2
New Part Numbers Serial Number Prefixes that Use the Part Numbers
319-0607 S/N:532, ; S/N:551, ; S/N:511, ; S/N:521, ; S/N:522, ; S/N:525, ; S/N:535, ; S/N:541, ; S/N:545, ; S/N:552, ; S/N:B3T, ; S/N:B9D, ; S/N:B9M, ; S/N:D9G
319-0674 S/N:C7D, ; S/N:C7P, ; S/N:C7Z, ; S/N:M7A
319-0675 S/N:HEP, ; S/N:BTM, ; S/N:CAP, ; S/N:CGZ, ; S/N:GAG, ; S/N:HAA, ; S/N:JAB, ; S/N:JCD, ; S/N:KDD, ; S/N:MCA, ; S/N:CYA, ; S/N:GKX, ; S/N:JNK, ; S/N:RBH, ; S/N:MKM, ; S/N:MSD, ; S/N:MSL, ; S/N:CEX, ; S/N:CEH, ; S/N:BCP, ; S/N:CLJ, ; S/N:AEM, ; S/N:AFM, ; S/N:BLE, ; S/N:BLT, ; S/N:BMK, ; S/N:BNL, ; S/N:BPM, ; S/N:BRJ, ; S/N:CAD, ; S/N:FDT, ; S/N:ACJ, ; S/N:ADE, ; S/N:BNC, ; S/N:BPP, ; S/N:BPZ, ; S/N:AAX, ; S/N:AGM, ; S/N:BMJ, ; S/N:BMY, ; S/N:BPS, ; S/N:BRZ, ; S/N:AEP, ; S/N:DAE, ; S/N:L5J, ; S/N:BRE
319-0676 S/N:101, ; S/N:102, ; S/N:103, ; S/N:104, ; S/N:125, ; S/N:202, ; S/N:301, ; S/N:302, ; S/N:AMZ, ; S/N:B1K, ; S/N:B2L, ; S/N:B3M, ; S/N:B4N, ; S/N:CAP, ; S/N:CBK, ; S/N:D3C, ; S/N:DKY
319-0677 S/N:ECH, ; S/N:AWN, ; S/N:CJX, ; S/N:JKR, ; S/N:JLS, ; S/N:JGK, ; S/N:BYE, ; S/N:T2D, ; S/N:DFP, ; S/N:SYM, ; S/N:JJG, ; S/N:LAB, ; S/N:EJC, ; S/N:KJR, ; S/N:PEH, ; S/N:CJM, ; S/N:GBR, ; S/N:KDG, ; S/N:KBE, ; S/N:DBH, ; S/N:SCR, ; S/N:GPB, ; S/N:PKE, ; S/N:C7K, ; S/N:C9M, ;