104742-4150 ZEXEL 9 460 614 491 BOSCH INJECTION-PUMP ASSEMBLY 9460614491 1047424150 167007t400

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 460 614 491 9460614491

ZEXEL 104742-4150 1047424150

NISSAN-DIESEL 167007T400 167007t400

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Cross reference number

BOSCH 9 460 614 491 9460614491

ZEXEL 104742-4150 1047424150

NISSAN-DIESEL 167007T400 167007t400

Zexel num

Bosch num

Firm num

Name

104742-4150

9 460 614 491

167007T400 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113orSAEJ967d

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

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

Injection timing adjustment

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 61.4 60.9 61.9

Difference in delivery mm3/st. 5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 40 36 44

Oil temperature degC 48 46 50

Injection timing adjustment_03

Pump speed r/min 760 760 760

Average injection quantity mm3/st. 49 45.5 52.5

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 61.4 60.4 62.4

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1140 1140 1140

Average injection quantity mm3/st. 62 58.5 65.5

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 1520 1520 1520

Average injection quantity mm3/st. 74 70.5 77.5

Oil temperature degC 50 48 52

Injection timing adjustment_07

Pump speed r/min 1900 1900 1900

Average injection quantity mm3/st. 73 68.5 77.5

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2150 2150 2150

Average injection quantity mm3/st. 16.6 13.6 19.6

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 52 50 54

Injection quantity adjustment_02

Pump speed r/min 2300 2300 2300

Average injection quantity mm3/st. 6

Oil temperature degC 52 50 54

Injection quantity adjustment_03

Pump speed r/min 2150 2150 2150

Average injection quantity mm3/st. 16.6 13.1 20.1

Difference in delivery mm3/st. 6

Basic *

Oil temperature degC 52 50 54

Governor adjustment

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 5.8 3.8 7.8

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 70 50 90

Basic *

Oil temperature degC 48 46 50

Remarks
IDLE

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 70 50 90

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_03

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 70 50 90

Oil temperature degC 48 46 50

Remarks
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

Speed control lever angle_02

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 5

Oil temperature degC 48 46 50

Remarks
Magnet OFF at full-load position

0000000901

Pump speed r/min 1140 1140 1140

Overflow quantity with S/T ON cm3/min 470 340 600

Oil temperature degC 50 48 52

Remarks
With an O-ring

_02

Pump speed r/min 1140 1140 1140

Overflow quantity with S/T ON cm3/min 470 340 600

Oil temperature degC 50 48 52

Remarks
Without an O-ring

Stop lever angle

Pump speed r/min 1140 1140 1140

Pressure with S/T OFF kPa 343 314 372

Pressure with S/T OFF kgf/cm2 3.5 3.2 3.8

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1140 1140 1140

Pressure with S/T OFF kPa 343 304 382

Pressure with S/T OFF kgf/cm2 3.5 3.1 3.9

Basic *

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1520 1520 1520

Pressure with S/T OFF kPa 412 334 471

Pressure with S/T OFF kgf/cm2 4.2 3.4 4.8

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1520 1520 1520

Timer stroke with S/T OFF mm 3.7 3.5 3.9

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1140 1140 1140

Timer stroke with S/T ON mm 2.5 2.5 2.5

Timer stroke with S/T OFF mm 1.3 0.9 1.9

Oil temperature degC 50 48 52

_03

Pump speed r/min 1520 1520 1520

Timer stroke with S/T OFF mm 3.7 3.3 4.1

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 2000 2000 2000

Timer stroke with S/T OFF mm 8.2 7.7 8.6

Oil temperature degC 50 48 52

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

Timing setting

K dimension mm 3.1 3 3.2

KF dimension mm 5.5 5.4 5.6

MS dimension mm 0.7 0.6 0.8

Pre-stroke mm 0.45 0.43 0.47

Control lever angle alpha deg. 25 21 29

Control lever angle beta deg. 36 31 41

Test data Ex:

0000001801 SUPPLY PUMP-TIMING DEVICE ADJ

Pump chamber pressure PT, timer stroke TA adjustment procedure Adjust the sequence in accordance with the procedure below. 1. At N = N1 set PT lower limit at P1. 2. At N = N2, set so that TA lower limit is TA1. 3. At N = N1 tap the regulating valve so that the timer's minimum specifications are obtained. 4. Reconfirm timer specifications for N = N2. (1)If as specified, confirm timer operation at N = N3. (2)If not as specified: 1) Readjust the timer at N = N2. (Adjust using the outer adjustable type). 2) Confirm timer operation at N = N1, N = N2. T:Tightening torque (A) = screw
----------
N1=1140r/min N2=1520r/min N3=2000r/min P1=314kPa(3.2kgf/cm2) TA1=3.5mm
----------
T=7~10N-m(0.7~1.0kgf-m)

0000001901 POTENTIOMETER ADJUSTMENT

Adjustment of the potentiometer In the following condition, change the installation position of the potentiometer to adjust the output voltage to within the specified values. At pump speed N1 and with the control lever angle at a (corresponding to a shim thickness of L1), measure the injection quantity Q. Then, determine the voltage Vo from the voltage formula F and adjust the potentiometer. J:Vo+-0.03 A = potentiometer performance specifications C = control lever position Q = injection quantity Vo = output voltage D = idle E = full speed Vi = applied voltage M = potentiometer graph O = output P output at connecting harnesses 2 and 3
----------
N1=1140r/min a=13.4deg L1=8.65mm
----------
V1=(1.65+-0.4)V V2=(10.0)V J=Vo+-0.03=0.0245Q+4.5723

Information:

Start By:a. remove turbocharger 1. Install the turbocharger on Tool (A).2. Put alignment marks on the two housings and cartridge assembly of the turbocharger for correct alignment during assembly.3. Loosen clamp (3), and remove compressor housing (4) from cartridge assembly (2).4. Loosen the remaining clamp, and remove cartridge assembly (2) from turbine housing (1).
Typical Example5. Put the cartridge group (shown in the illustration) with nut (16) up in Tool (B). Use a 5S9566 Sliding T-Wrench and a universal socket to remove nut (16) that holds the compressor wheel (15) to the wheel assembly (19).6. Remove compressor wheel (15) and housing assembly (6) from wheel assembly (19). Remove piston ring (13) from the wheel assembly.7. Use Tool (C), and remove snap ring (5) from housing assembly (6). Remove insert (14) and sleeve (18) from the housing assembly. Remove seal (22) from insert (14). Remove ring (20) from sleeve (18).8. Remove oil deflector (23), thrust ring (21), bearing assembly (7), spacer sleeve (24) and thrust ring (8) from housing assembly (6).9. Use Tool (D), and remove snap ring (9) from the housing assembly. Remove bearing (25). Remove snap ring (10) with Tool (D).10. Use Tool (D), and remove snap ring (12) from the housing assembly. Remove bearing (26). Remove snap ring (11) with Tool (D).11. Check all the parts of the turbocharger for damage. If any parts are damaged, use new parts for replacement. See Special Instruction Form No. SMHS6854 for turbocharger reconditioning. Also, see Guidelines For Reusable Parts, Form No. SEBF8018. The following steps are for assembly of the turbocharger.12. Make sure that all the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material. Do not put oil on any parts of the turbocharger until after the compressor wheel has been installed. After the turbocharger has been assembled, put clean engine oil into the oil inlet of the turbocharger.
Make sure the snap rings that hold bearings (25) and (26) in housing assembly (6) are installed with the round edge of the outside diameter toward the bearing.
13. Install snap ring (11) with Tool (D). Install bearing (26). Install snap ring (12) with Tool (D).14. Install snap ring (10) with Tool (D). Install bearing (25). Install snap ring (9) with Tool (D).15. Put wheel assembly (19) in position on Tool (B) with the threaded portion end up. Put 6V2055 High Vacuum Grease in the groove for piston ring (13) at assembly to one half or more of the depth of the groove all the way around.16. Install piston ring (13) in the groove in wheel assembly (19).17. Put housing assembly (6) in position on wheel assembly (19).18. Install thrust ring (8) and spacer sleeve (24) on wheel assembly (19).19. Make sure the screen is in place in bearing assembly (7). Install bearing assembly (7) over spacer sleeve (24). Make sure the screen in the bearing assembly is facing toward housing assembly (6) when it is installed.20. Install thrust ring (21) and oil deflector (23)