Information injection-pump assembly
BOSCH
9 400 616 865
9400616865
ZEXEL
106671-5572
1066715572
NISSAN-DIESEL
1671396970
1671396970
Rating:
Service parts 106671-5572 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
22.6/230
15.
NOZZLE SET
Include in #1:
106671-5572
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 616 865
9400616865
ZEXEL
106671-5572
1066715572
NISSAN-DIESEL
1671396970
1671396970
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
132424-0620
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
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
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
Cal 1-5 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
11.4
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
161
159
163
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the lever
*
Boost pressure
kPa
72
72
Boost pressure
mmHg
540
540
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.7+-0.5
Pump speed
r/min
270
270
270
Average injection quantity
mm3/st.
15.5
14.5
16.5
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
D
Rack position
8.95
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
90
87
93
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
350
350
350
Rack position
8.95
Boost pressure
kPa
13.3
12
14.6
Boost pressure
mmHg
100
90
110
Boost compensator adjustment_02
Pump speed
r/min
350
350
350
Rack position
10.35
Boost pressure
kPa
30
26
34
Boost pressure
mmHg
225
195
255
Boost compensator adjustment_03
Pump speed
r/min
350
350
350
Rack position
12.4+0.2
Boost pressure
kPa
58.7
58.7
58.7
Boost pressure
mmHg
440
440
440
Timer adjustment
Pump speed
r/min
875--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
825
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
925
Advance angle
deg.
1
0.5
1.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Tolerance for racks not indicated: +-0.05mm.
(2)Rack limit using stop lever: R1 (at N = N1)
(3)Boost compensator stroke: BCL
(4)Damper spring setting
(5)Rack difference between N = N2 and N = N3
(6)Variable speed specification: idling adjustment
(7)Fix the lever at the full-load position at delivery.
(8)Main spring setting
----------
R1=12.4+0.2mm N1=350r/min BCL=(3.55)mm N2=1100r/min N3=650r/min
----------
----------
R1=12.4+0.2mm N1=350r/min BCL=(3.55)mm N2=1100r/min N3=650r/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=290r/min
----------
a=(16deg)+-5deg b=(7deg)+-5deg
----------
aa=290r/min
----------
a=(16deg)+-5deg b=(7deg)+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
(2)Use the hole at R = aa
----------
aa=42mm
----------
a=30.5deg+-3deg b=45deg+-5deg
----------
aa=42mm
----------
a=30.5deg+-3deg b=45deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position aa (pump speed bb r/min )
(2)Use the pin above R = cc
----------
aa=12.4+0.2mm bb=350r/min cc=40mm
----------
a=41deg+-5deg b=41deg+-5deg
----------
aa=12.4+0.2mm bb=350r/min cc=40mm
----------
a=41deg+-5deg b=41deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(30deg)
----------
----------
a=(30deg)
Information:
Right Side (6 Cylinder Shown)(1) Depth that cup plugs are installed (measured from block face to top edge of plug) ... 1.25 0.25 mm (.049 .010 in)(2) Distance all sleeves extend from top face ... 14 2 mm (.55 .08 in)(3) Distance two large dowels extend from rear face ... 12.0 0.5 mm (.47 .02 in)(4) Distance two small dowels extend from rear face ... 8.0 0.5 mm (.31 .02 in)(5) Distance all dowels extend from front face ... 8.0 0.5 mm (.31 .02 in)
View A-A (Rear Face)(6) Bores in block for all camshaft bearings except front bearing ... 69.000 0.038 mm (2.7165 .0015 in)(7) Locate bearing oil hole for all camshaft bearings (except front bearing) at top of bore.
Front Face(8) Bore in block for front camshaft bearing ... 70.000 0.025 mm (2.7559 .0010 in)(9) Front camshaft bearing joint location.(10) Front camshaft bearing oil hole. Install front camshaft bearing with bearing oil hole (10) aligned with oil hole in block and bearing joint (9) positioned as shown.(11) Width of main bearing cap ... 159.995 0.020 mm (6.2990 .0008 in) Width of cylinder block for main bearing cap ... 160.000 0.018 mm (6.2992 .0007 in)(12) Bore in block for main bearings ... 95.000 0.013 mm (3.7402 .0005 in)(13) Main bearing cap bolts. Install as follows: Install bearing caps with sequence number to the right, 1 through 5 (for 4 cylinder) or 1 through 7 (for 6 cylinder), front to rear.a. Before assembly, put 2P2506 Thread Lubricant on the bolt threads and washer face.b. Tighten both bolts of each bearing cap to a torque of ... 54 7 N m (40 5 lb ft)c. Then tighten bolts an additional ... 90 5 degrees (1/4 turn)(14) Location of bearing cap sequence number.(15) Dimension from centerline of crankshaft bore to pan rail ... 110.00 mm (4.331 in)(16) Dimension from centerline of crankshaft bore to top of block ... 322.00 .017 mm (12.677 .0007 in)(17) Cylinder bore size ... 105.025 .025 mm (4.1348 .0010 in) Bore size must be checked with a 4C4377 Cylinder Head Stress Plate and gasket installed. Refer to Installation Of 7C6208 Cylinder Sleeve, Special Instruction Form No. SEHS9047. (18) Piston cooling jet. Check piston cooling jets by inserting a 1.3 mm (.05 in) diameter drill rod into jet. Rod must pass through a 5.0 mm (.20 in) diameter circle in location (A) and a 13 mm (.51 in) diameter circle in location (B). Dimension (C) is 25.9 mm (1.02 in). Dimension (D) is 33.4 mm (1.31 in). Dimension (E) is 26.95 mm (1.061 in). Dimension (F) is 9.8 mm (.39 in). Dimension (G) is 50 mm (2.0 in). Distance four sleeves (19) extend from side face ... 5.0 0.5 mm (.20 .02 in)