106661-5561 ZEXEL 9 400 612 462 BOSCH INJECTION-PUMP ASSEMBLY 9400612462 1066615561 1671396912

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 612 462 9400612462

ZEXEL 106661-5561 1066615561

NISSAN-DIESEL 1671396912 1671396912

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Service parts 106661-5561 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106066-5710

3. GOVERNOR 105487-6340

4. SUPPLY PUMP 105217-1850

5. AUTOM. ADVANCE MECHANIS 105636-2700

6. COUPLING PLATE 105662-1200

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5700

11. Nozzle and Holder 16600-96508

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105031-4370

14. NOZZLE

105015-5290

15. NOZZLE SET

Include in #1:

106661-5561 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 462 9400612462

ZEXEL 106661-5561 1066615561

NISSAN-DIESEL 1671396912 1671396912

Zexel num

Bosch num

Firm num

Name

106661-5561

9 400 612 462

1671396912 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
PE6 K 14CA INJECTION PUMP ASSY PE6P,6PD 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 8-3-600

Overflow valve 132424-0620

Overflow valve opening pressure kPa 157 157 157

Overflow valve opening pressure kgf/cm2 1.6 1.6 1.6

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 3.65 3.6 3.7

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 A

Rack position 9

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 124.5 122.5 126.5

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 5+-0.5

Pump speed r/min 260 260 260

Average injection quantity mm3/st. 10.5 9.2 11.8

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Timer adjustment

Pump speed r/min -

Advance angle deg. 0 0 0

Remarks
Measure speed (beginning of operation).

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 5 4.5 5.5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Rack limit using the stop lever: R1 (5)Excess fuel setting for starting: SXL (N = N1) (6)Damper spring setting (7)Variable speed specification: idling adjustment (8)Fix the lever at the full-load position at delivery. (9)Main spring setting
----------
RT=1 TH=2.2mm R1=10.5+-0.1mm SXL=9+0.2mm N1=400r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Pump speed = aa (2)Set the stopper bolt (fixed at full-load position at delivery.)
----------
aa=275r/min
----------
a=26.5deg+-5deg b=15deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=29deg+-3deg b=41deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Drive side (3)Rack position bb
----------
aa=50mm bb=10.5+-0.1mm
----------
a=25deg+-5deg b=27deg+-5deg

Timing setting

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

----------
a=(25deg)

Information:

Install the pump cover onto the pump housing. Tighten the four middle bolts. Then, tighten the end bolts in a crisscross pattern. Tighten the bolts to a torque of 10.2 N m (90 lb in).Note: Make sure that the gasket is in place between the housing and the cover.
Repeat Step 1 and Step 2 in order to confirm the electrical connection for the pump coil was not damaged during the removal of the pump cover.
Install the oil inlet line adapter, inlet line, and harness connector to the pump.Note: After the HEUI pump is replaced or reassembled, the engine must be cranked for an extended length of time to fill the pump with oil.Note: Clear any diagnostic or event codes that activated during the initial start-up.
If the engine would not start before inspecting for debris and no debris was found in the HEUI pump, return to Step D in the diagnostic flow chart.If the engine would start before inspecting for debris and no debris was found in the HEUI pump, return to Step L in the diagnostic flow chart.If the pump is to be replaced, complete the checklist form in Special Instruction, REHS5031 that is provided with the service replacement part and insert the completed form back into the box containing the part that is being returned. Proceed to the section of this instruction titled "Oil Rail Cleaning Procedure" for the correct engine size that is being serviced.Oil Rail Cleaning Procedure For the C7 Engine
Illustration 12 g02702636
C7 Cylinder Head
Illustration 13 g02708256
The oil and fuel passages are the same for both the C7 and C9.
(6) Oil Rail for a HEUI fuel system
(7) Oil passage to injector bore
(8) Fuel passage
(9) Injector bore Note: Contain any oil and cleaner that will flow from the cylinder and the lines during the following process. Properly dispose of the oil and contaminated cleaner when work is complete.
Remove fuel injectors. Refer to Disassembly and Assembly for specific machine.
Install six plugs 9U-7080 Tapered Cap/Plug into the lower injector bores. The plugs will prevent oil, cleaners, and debris from entering the cylinders.
Remove the plugs from the front and rear of the cylinder head main oil gallery
Remove the pressure sensor from the cylinder head. Protect the sensor.
Clean out the two rail drain holes by removing their plugs and using the brake cleaner and long squirting straw to flush these passages to the oil rail.
Using the solvent gun with and without the