106691-0203 ZEXEL 9 400 617 749 BOSCH INJECTION-PUMP ASSEMBLY 9400617749 1066910203 1671396671

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 617 749 9400617749

ZEXEL 106691-0203 1066910203

NISSAN-DIESEL 1671396671 1671396671

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Cross reference number

BOSCH 9 400 617 749 9400617749

ZEXEL 106691-0203 1066910203

NISSAN-DIESEL 1671396671 1671396671

Zexel num

Bosch num

Firm num

Name

106691-0203

9 400 617 749

1671396671 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
PE6T * K

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 (drive side) 134424-1720

Overflow valve opening pressure (drive side) kPa 162 147 177

Overflow valve opening pressure (drive side) kgf/cm2 1.65 1.5 1.8

Overflow valve (governor side) 132424-0620

Overflow valve opening pressure (governor side) kPa 157 123 191

Overflow valve opening pressure (governor side) 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 3.65 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 11.1

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 162 160 164

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Boost pressure kPa 30.7 30.7

Boost pressure mmHg 230 230

Injection quantity adjustment_02

Adjusting point B

Rack position 10.8+-0. 5

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 162.2 159.2 165.2

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Boost pressure kPa 30.7 30.7

Boost pressure mmHg 230 230

Injection quantity adjustment_03

Adjusting point C

Rack position 6+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 13.2 12.2 14.2

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_04

Adjusting point D

Rack position R1(9.5)

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 112 109 115

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 300 300 300

Rack position R1(9.5)

Boost pressure kPa 6.7 4 6.7

Boost pressure mmHg 50 30 50

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position 11.7

Boost pressure kPa 24

Boost pressure mmHg 180

Timer adjustment

Pump speed r/min 200+100

Advance angle deg. 1.6 1.1 2.1

Remarks
Start

Timer adjustment_02

Pump speed r/min 500-150

Advance angle deg. 0 0 0

Timer adjustment_03

Pump speed r/min 910+80

Advance angle deg. 0 0 0

Timer adjustment_04

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)Damper spring setting: DL (2)Boost compensator stroke (3)Rack limit using the stop lever: R1 (4)Variable speed specification. (5)Main spring setting (6)Set idle sub-spring
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DL=5-0.2mm R1=11.7+-0.1mm
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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=26deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
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a=20.5deg+-5deg b=35deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb, pump speed cc
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aa=11.7mm bb=1+0.5mm cc=0r/min
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a=28deg+-5deg b=30deg+-3deg

0000001501 Q ADJUSTMENT PIPING

Tester fuel pipe A Fuel inlet B (C) Forked piping (D) Overflow valve Piping at standard injection quantity adjustment 1. Because the pump gallery is divided into two, be careful of the fuel piping at adjustment.
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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=(30deg)

Information:

Start By:a. remove oil pan 1. Remove bolts (1) that hold main bearing cap (2) in place. Remove main cap (2).2. Remove the bearing half from the cap.
If the crankshaft is turned in the wrong direction, the tab of the bearing will be pushed between the crankshaft and cylinder block. This can cause damage to either or both the crankshaft and cylinder block.
3. Remove the upper half of main bearings (3) as follows: a. Turn the crankshaft until tool (A) can be installed in the crankshaft journal. Install tool (A).b. Turn the crankshaft in the direction which will push the upper main bearing out, tab end first.c. Check the condition of the bearings. See "Guideline For Reusable Parts", "Main And Connecting Rod Bearings", Form No. SEBF8009 and SEBD0531. The following steps are for the installation of the crankshaft main bearings. Put clean engine oil on the main bearings for the assembly. Also, be sure the tabs on the back side of the main bearings fit in the grooves of the main bearings caps and cylinder block.
Ensure that the bearings are installed in the correct locations. Two different part numbers are used in the quantities of three and four. The part number having the quantity of four is to be installed on crankshaft main bearings 2, 3, 5 and 6. The part number having the quantity of three is to be installed on crankshaft bearing 1, 4 and 7.
4. Clean the surfaces in the cylinder block for the main bearings. Use tool (A), and install new upper halves of main bearings (bearings with the oil hole) in the cylinder block. Do not put oil on the back of the bearing.5. Clean the mating surface of the main bearing caps for the main bearings. Install the new lower halves of the main bearings in the main caps. Do not put oil on the back of the bearing.
Main bearing caps should be installed with the part number towards the right side. Caps are to be identified by stamped numbers 1 thru 7 located on the bottom unmachined surface.
6. Put main bearing caps (2) in position on the cylinder block. put clean engine oil or molylube on the bolt threads and the washer face; then install the bolts. Tighten the bolts on the side where the main bearing tabs are located to a torque of 95 5 N m (70 4 lb ft). Tighten the bolts on the opposite side to a torque of 95 5 N m (70 4 lb ft).7. Put a mark on each bolt head and the bearing caps. Turn the bolts that are opposite the main bearing tabs an additional 90° 5° turn. Then turn the bolts on the side where the main bearing tabs are located an additional 90° 5° turn.
Typical Example8. Check the end play of the crankshaft with a dial indicator and magnetic base. The end play must be 0.10 to 0.50 mm (.004 to .020 in). The