Information injection-pump assembly
BOSCH
9 460 611 560
9460611560
ZEXEL
104741-4570
1047414570
NISSAN
167006T303
167006t303
Rating:
Cross reference number
BOSCH
9 460 611 560
9460611560
ZEXEL
104741-4570
1047414570
NISSAN
167006T303
167006t303
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113orSASEJ967d
1404 Test oil ISO4113orSASEJ967d
Test oil temperature
degC
45
45
50
Nozzle
105780-0060
Bosch type code
NP-DN0SD1510
Nozzle holder
105780-2150
Opening pressure
MPa
13
13
13.3
Opening pressure
kgf/cm2
133
133
136
Injection pipe
157805-7320
Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-450
Inside diameter - outside diameter - length (mm) mm 2-6-450
Joint assembly
157641-4720
Tube assembly
157641-4020
Transfer pump pressure
kPa
20
20
20
Transfer pump pressure
kgf/cm2
0.2
0.2
0.2
Direction of rotation (viewed from drive side)
Right R
Right R
Injection timing adjustment
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
57.3
56.8
57.8
Difference in delivery
mm3/st.
4.5
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_02
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
53.2
49.7
56.7
Oil temperature
degC
48
46
50
Injection timing adjustment_03
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
54.8
51.3
58.3
Oil temperature
degC
50
48
52
Injection timing adjustment_04
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
57.3
56.3
58.3
Difference in delivery
mm3/st.
5
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_05
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
57
53.5
60.5
Oil temperature
degC
50
48
52
Injection timing adjustment_06
Pump speed
r/min
1800
1800
1800
Average injection quantity
mm3/st.
57.3
53.8
60.8
Oil temperature
degC
50
48
52
Injection quantity adjustment
Pump speed
r/min
2350
2350
2350
Average injection quantity
mm3/st.
19.2
17.2
21.2
Basic
*
Oil temperature
degC
52
50
54
Injection quantity adjustment_02
Pump speed
r/min
2350
2350
2350
Average injection quantity
mm3/st.
19.2
16.7
21.7
Basic
*
Oil temperature
degC
52
50
54
Injection quantity adjustment_03
Pump speed
r/min
2600
2600
2600
Average injection quantity
mm3/st.
5
Oil temperature
degC
55
52
58
Governor adjustment
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
10.9
8.9
12.9
Difference in delivery
mm3/st.
2
Basic
*
Oil temperature
degC
48
46
50
Governor adjustment_02
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
10.9
8.4
13.4
Difference in delivery
mm3/st.
2.5
Basic
*
Oil temperature
degC
48
46
50
Timer adjustment
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
90
75
110
Oil temperature
degC
48
46
50
Remarks
Full
Full
Timer adjustment_02
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
90
75
110
Oil temperature
degC
48
46
50
Remarks
Full
Full
Speed control lever angle
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
0
0
0
Oil temperature
degC
48
46
50
Remarks
Magnet OFF at idling position
Magnet OFF at idling position
Speed control lever angle_02
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
0
0
0
Oil temperature
degC
48
46
50
Remarks
Magnet OFF at idling position
Magnet OFF at idling position
0000000901
Pump speed
r/min
1000
1000
1000
Overflow quantity with S/T ON
cm3/min
500
370
630
Oil temperature
degC
50
48
52
_02
Pump speed
r/min
1000
1000
1000
Overflow quantity with S/T ON
cm3/min
500
370
630
Oil temperature
degC
50
48
52
Stop lever angle
Pump speed
r/min
1000
1000
1000
Pressure with S/T ON
kPa
618
579
657
Pressure with S/T ON
kgf/cm2
6.3
5.9
6.7
Pressure with S/T OFF
kPa
539
519
559
Pressure with S/T OFF
kgf/cm2
5.5
5.3
5.7
Basic
*
Oil temperature
degC
50
48
52
Stop lever angle_02
Pump speed
r/min
1000
1000
1000
Pressure with S/T OFF
kPa
539
500
578
Pressure with S/T OFF
kgf/cm2
5.5
5.1
5.9
Basic
*
Oil temperature
degC
50
48
52
Stop lever angle_03
Pump speed
r/min
1800
1800
1800
Pressure with S/T OFF
kPa
736
677
795
Pressure with S/T OFF
kgf/cm2
7.5
6.9
8.1
Oil temperature
degC
50
48
52
0000001101
Pump speed
r/min
1000
1000
1000
Timer stroke with S/T ON
mm
5.5
5.1
5.9
Timer stroke with S/T OFF
mm
3.9
3.7
4.1
Basic
*
Oil temperature
degC
50
48
52
_02
Pump speed
r/min
600
600
600
Timer stroke with S/T OFF
mm
0.9
0.3
1.5
Oil temperature
degC
50
48
52
_03
Pump speed
r/min
1000
1000
1000
Timer stroke with S/T ON
mm
5.5
5
6
Timer stroke with S/T OFF
mm
3.9
3.6
4.2
Basic
*
Oil temperature
degC
50
48
52
_04
Pump speed
r/min
1800
1800
1800
Timer stroke with S/T OFF
mm
8.2
7.7
8.7
Oil temperature
degC
50
48
52
_05
Pump speed
r/min
2050
2050
2050
Timer stroke with S/T OFF
mm
8.2
7.7
8.6
Oil temperature
degC
52
50
54
0000001201
Max. applied voltage
V
8
8
8
Test voltage
V
13
12
14
0000001401
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
35
34.5
35.5
Timer stroke TA
mm
2.9
2.7
3.1
Timer stroke variation dT
mm
1
1
1
Basic
*
Oil temperature
degC
50
48
52
_02
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
35
34
36
Timer stroke TA
mm
2.9
2.3
3.5
Timer stroke variation dT
mm
1
1
1
Basic
*
Oil temperature
degC
50
48
52
_03
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
20
17.5
22.5
Timer stroke TA
mm
1.7
1.2
2.2
Timer stroke variation dT
mm
2.2
2.2
2.2
Oil temperature
degC
50
48
52
Timing setting
K dimension
mm
3.3
3.2
3.4
KF dimension
mm
5.62
5.52
5.72
MS dimension
mm
0.9
0.8
1
Pre-stroke
mm
0.1
0.08
0.12
Control lever angle alpha
deg.
55.5
51.5
59.5
Control lever angle beta
deg.
34
29
39
Test data Ex:
0000001801 POTENTIOMETER ADJUSTMENT
Boost pressure P1kPa {P2 mmHg}
Switch voltage is the value when the idle lever position is 0 V.
* Adjusting method of the 1 potentiometer (P/M)
Substitute the actual measurement of the angle a of each I/P in the following formula and determine the P/M output adjustment y (V).
When the angle a <= c: y = 6.27
When c < angle a < d: y=6.27 + (angle a - 28.5) x 0.163
When d <alpha <e: y=7.57
A:Potentiometer standards
B:ON, OFF switch standard
G:ON-->OFF
D:OFF-->ON
E:Adjusting point
F:Checking point
P:Boost pressure
Vi:Applied voltage
C1:Full-speed
C2:Idle
Q:Injection quantity
N:Pump speed
V:Output voltage
C:Control lever angle
----------
c=30deg d=38deg e=-deg Vi=10V
----------
V1=a+-0.03V V2=1.22+-0.56V V3=1.41+-0.81V V4=3.71+-0.82V f:8.5+-5.5deg g:22.3+-6deg
----------
c=30deg d=38deg e=-deg Vi=10V
----------
V1=a+-0.03V V2=1.22+-0.56V V3=1.41+-0.81V V4=3.71+-0.82V f:8.5+-5.5deg g:22.3+-6deg
Information:
Flywheel
Installation of Flywheel Housing
Installation of flywheel housing(1) Install the oil seal to the flywheel housing.(2) Coat the contact surfaces of the crankcase and flywheel with ThreeBond 1104.(3) Align the holes in the flywheel housing and gasket with the dowel pins on the crankcase, and install them to the crankcase.Installation of Flywheel
(1) Install the flywheel to the crankshaft by aligning the hole with the dowel pin on the back-end of the crankshaft.(2) Place the washer and tighten the four bolts to the specified torque.
Installation of flywheelMeasurement of Flywheel Runout
Measure the flywheel runout with the flywheel installed to the crankshaft. If the standard value is exceeded, check the bolts for tightening condition and the mounting face for adhesion of foreign particles.
Measurement of face runout and circular runoutCylinder Head and Valve Mechanisms
Installation of Valve Stem Seal
(1) Apply engine oil to the valve stem, and insert it into the valve guide.(2) Place a new stem seal on the valve guide.(3) Using the stem seal installer, install the stem seal to the valve guide, making use of the valve stem as a guide.
Installation of valve stem sealInstallation of Valves and Valve Springs
(1) Place the valve spring and retainer on the valve guide, and install the valve cotter using the valve spring pusher.
Excessive compression of the valve spring can cause the retainer to contact the stem seal and damage the seal.
Installation of valve and valve spring(2) Using a soft-faced hammer, tap the top of the valve stem several times to make sure that the spring and valve cotter are securely installed.
Confirmation of secure valve cotter installationInstallation of Cylinder Head Gasket
(1) Make sure that the top face of the crankcase and piston upper surfaces are clean and free of dust.(2) Place a new gasket of the crankcase, making sure that the dowel pins on the top face of the crankcase enter the holes in the gasket.
Do not use a liquid gasket.
Installation of cylinder head gasketInstallation of Cylinder Head
Place the cylinder head on the head gasket, making sure that the dowel pins on the top face of the crankcase enters the holes in the cylinder head.
Installation of cylinder head assemblyTightening of Cylinder Head Bolts
Tighten the cylinder head bolts, following the tightening sequence shown in the diagram two or three times before reaching the specified torque.
Cylinder head bolt tightening sequenceAssembly of Rocker Arm and Rocker Shaft Assembly
When installing the rocker arms, make sure that the shaft assembly marks face the front of the engine, as shown in the diagram. After the assembly, make sure that the rocker arms move smoothly.
Assembly of rocker shaft assemblyInstallation of Pushrods
(1) Insert the pushrods in the cylinder head through the pushrod holes.(2) Make sure that the ball end of each pushrod rests securely on the curved surface of the tappet.Installation of Rocker Shaft Assemblies
(1) Install the valve caps.(2) When installing the rocker shaft brackets, tighten the long bolts first, then tighten the short bolts (reversal of removal sequence).
Installation of rocker shaft assemblyAdjustment of Valve Clearances
(1) Confirming the top dead center on the
Installation of Flywheel Housing
Installation of flywheel housing(1) Install the oil seal to the flywheel housing.(2) Coat the contact surfaces of the crankcase and flywheel with ThreeBond 1104.(3) Align the holes in the flywheel housing and gasket with the dowel pins on the crankcase, and install them to the crankcase.Installation of Flywheel
(1) Install the flywheel to the crankshaft by aligning the hole with the dowel pin on the back-end of the crankshaft.(2) Place the washer and tighten the four bolts to the specified torque.
Installation of flywheelMeasurement of Flywheel Runout
Measure the flywheel runout with the flywheel installed to the crankshaft. If the standard value is exceeded, check the bolts for tightening condition and the mounting face for adhesion of foreign particles.
Measurement of face runout and circular runoutCylinder Head and Valve Mechanisms
Installation of Valve Stem Seal
(1) Apply engine oil to the valve stem, and insert it into the valve guide.(2) Place a new stem seal on the valve guide.(3) Using the stem seal installer, install the stem seal to the valve guide, making use of the valve stem as a guide.
Installation of valve stem sealInstallation of Valves and Valve Springs
(1) Place the valve spring and retainer on the valve guide, and install the valve cotter using the valve spring pusher.
Excessive compression of the valve spring can cause the retainer to contact the stem seal and damage the seal.
Installation of valve and valve spring(2) Using a soft-faced hammer, tap the top of the valve stem several times to make sure that the spring and valve cotter are securely installed.
Confirmation of secure valve cotter installationInstallation of Cylinder Head Gasket
(1) Make sure that the top face of the crankcase and piston upper surfaces are clean and free of dust.(2) Place a new gasket of the crankcase, making sure that the dowel pins on the top face of the crankcase enter the holes in the gasket.
Do not use a liquid gasket.
Installation of cylinder head gasketInstallation of Cylinder Head
Place the cylinder head on the head gasket, making sure that the dowel pins on the top face of the crankcase enters the holes in the cylinder head.
Installation of cylinder head assemblyTightening of Cylinder Head Bolts
Tighten the cylinder head bolts, following the tightening sequence shown in the diagram two or three times before reaching the specified torque.
Cylinder head bolt tightening sequenceAssembly of Rocker Arm and Rocker Shaft Assembly
When installing the rocker arms, make sure that the shaft assembly marks face the front of the engine, as shown in the diagram. After the assembly, make sure that the rocker arms move smoothly.
Assembly of rocker shaft assemblyInstallation of Pushrods
(1) Insert the pushrods in the cylinder head through the pushrod holes.(2) Make sure that the ball end of each pushrod rests securely on the curved surface of the tappet.Installation of Rocker Shaft Assemblies
(1) Install the valve caps.(2) When installing the rocker shaft brackets, tighten the long bolts first, then tighten the short bolts (reversal of removal sequence).
Installation of rocker shaft assemblyAdjustment of Valve Clearances
(1) Confirming the top dead center on the