106671-5690 ZEXEL 9 400 616 871 BOSCH INJECTION-PUMP ASSEMBLY 9400616871 1066715690 1679096608

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 616 871 9400616871

ZEXEL 106671-5690 1066715690

NISSAN-DIESEL 1679096608 1679096608

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Service parts 106671-5690 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106067-1360

3. GOVERNOR 105407-6780

4. SUPPLY PUMP 105217-1860

5. AUTOM. ADVANCE MECHANIS 105681-2370

6. COUPLING PLATE 105663-0650

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-7670

11. Nozzle and Holder 1660096611

12. Open Pre:MPa(Kqf/cm2) 18.6{190}/22.6{230}

13. NOZZLE-HOLDER 105041-4190

14. NOZZLE

15. NOZZLE SET 105019-0471

Include in #1:

106671-5690 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 616 871 9400616871

ZEXEL 106671-5690 1066715690

NISSAN-DIESEL 1679096608 1679096608

Zexel num

Bosch num

Firm num

Name

106671-5690

9 400 616 871

1679096608 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
PF6T24 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 134424-0020

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-4-2-6- 3-5

Pre-stroke mm 3.9 3.85 3.95

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 12

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 175.5 173.5 177.5

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 6.5+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 14.5 13.5 15.5

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 300 300 300

Rack position 9.6

Boost pressure kPa 6.7 1.4 12

Boost pressure mmHg 50 10 90

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position 12

Boost pressure kPa 37.3 34.6 40

Boost pressure mmHg 280 260 300

Boost compensator adjustment_03

Pump speed r/min 300 300 300

Rack position (13.2)

Boost pressure kPa 58.7 58.7 58.7

Boost pressure mmHg 440 440 440

Timer adjustment

Pump speed r/min 750--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 700

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1050

Advance angle deg. 2 1.5 2.5

Remarks
Finish

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)Boost compensator stroke: BCL (4)Set idle sub-spring (5)Main spring setting
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K=9 BCL=(3.6)mm
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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a=(10deg)+-5deg b=(22deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=26.5deg+-5deg b=53deg+-5deg

0000001501 GOV FULL LOAD ADJUSTMENT

Title1:Full load stopper adjustment Title2:Governor set speed LABEL1:Distinguishing LABEL2:Pump speed (r/min) LABEL3:Ave. injection quantity (mm3/st) LABEL4:Max. var. bet. cyl. LABEL5:Remarks LABEL6:Distinguishing LABEL7:Governor set speed (r/min) LABEL8:Maximum no-load speed (r/min) LABEL9:Remarks (1)Adjustment conditions are the same as those for measuring injection quantity. (2)At high idle rack position L
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L=6.5mm
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a1=B a2=- a3=- a4=- r1=1050r/min r2=- r3=- r4=- Q1=175.5+-2mm3/st Q2=- Q3=- Q4=- c1=+-4% c2=- c3=- c4=- a5=21 a6=20 a7=19 a8=18 a9=17 a10=16 a11=15 a12=14 a13=- a14=- a15=- r5=1050r/min r6=1000r/min r7=950r/min r8=900r/min r9=850r/min r10=800r/min r11=750r/min r12=700r/min r13=- r14=- r15=- R5=1130+-26r/min R6=1075+-25r/min R7=1020+-23r/min R8=965+-22r/min R9=915+-22r/min R10=865+-20r/min R11=820+-18r/min R12=775+-18r/min R13=- R14=- R15=-

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
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----------
a=(20deg)

Information:

1. Remove the bolts that hold the cylinder head assembly to the cylinder block.
To prevent damage to the two cylinder head-to-cylinder block dowels, keep the cylinder head assembly level during removal and installation.
2. Fasten a hoist to the cylinder head assembly as shown. Carefully remove the cylinder head assembly from the cylinder block. Remove the cylinder head gasket. The weight of the cylinder head assembly can range from 50 to 75 kg (110 to 165 lb). The following steps are for the installation of the cylinder head assembly.3. Be sure the mating surface of the cylinder head assembly and the cylinder block are thoroughly clean.4. Put a new cylinder head gasket in position on the cylinder block. Be sure the head gasket is dry. Fasten a hoist to the cylinder head assembly, and put it in position on the cylinder block.
3114 Cylinder Head Tightening Sequence
3116 Cylinder Head Tightening Sequence Bolts (1) are large diameter bolts (M20). Bolts (2) are small diameter bolts (M10).5. Apply clean engine oil on the threads of the cylinder head assembly mounting bolts.6. Install the bolts that hold the cylinder head assembly to the cylinder block, and tighten them as follows: a. Tighten the large diameter bolts in the number sequence shown to a torque of 150 15 N m (110 11 lb ft).b. Tighten the large diameter bolts in the number sequence shown to a torque of 435 20 N m (320 15 lb ft).c. Retorque the large diameter bolts in the number sequence shown to a torque of 435 20 N m (320 15 lb ft).d. Tighten the small diameter bolts in the number sequence shown to a torque of 55 7 N m (41 5 lb ft).End By:a. install unit fuel injectorsb. install fuel control linkagec. install rocker arm assemblies and push rodsd. install inlet manifolde. install exhaust manifoldf. install fuel filter and fuel filter base