106871-0453 ZEXEL 9 400 618 025 BOSCH INJECTION-PUMP ASSEMBLY 9400618025 1068710453 1670097614

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 025 9400618025

ZEXEL 106871-0453 1068710453

NISSAN-DIESEL 1670097614 1670097614

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Service parts 106871-0453 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-7520

3. GOVERNOR 105306-0932

4. SUPPLY PUMP

105237-4180

5. AUTOM. ADVANCE MECHANIS 105636-2790

6. COUPLING PLATE 105662-1150

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5840

11. Nozzle and Holder 1660097019

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

13. NOZZLE-HOLDER 105031-4210

14. NOZZLE

105015-5450

15. NOZZLE SET

Include in #1:

106871-0453 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 025 9400618025

ZEXEL 106871-0453 1068710453

NISSAN-DIESEL 1670097614 1670097614

Zexel num

Bosch num

Firm num

Name

106871-0453

9 400 618 025

1670097614 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
RE8 * 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 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 1-8-7-5- 4-3-6-2

Pre-stroke mm 3.65 3.6 3.7

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-8 deg. 45 44.5 45.5

Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5

Difference between angles 3
Cal 1-5 deg. 135 134.5 135.5

Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 5
Cal 1-3 deg. 225 224.5 225.5

Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5

Difference between angles 7
Cyl.1-2 deg. 315 314.5 315.5

Injection quantity adjustment

Adjusting point A

Rack position 10.2

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 105.2 104.2 106.2

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 5.7+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 11.3 9.3 13.3

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Timer adjustment

Pump speed r/min 750

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 1.4 0.9 1.9

Timer adjustment_03

Pump speed r/min 1150

Advance angle deg. 5.5 5 6

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Rack limit using the stop lever: R1 (2)Damper spring setting: DL (3)Rack difference from N = N1
----------
R1=10.6+0.2mm DL=5.7-0.2mm N1=700r/min
----------

0000000901

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

----------
a=16deg+-5deg b=17deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa
----------
aa=10.6+0.2mm
----------
a=12deg+-5deg b=31deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of the coupling's key groove at the beginning of injection of the No. 8 cylinder. (3)- (4)-
----------

----------
a=(90deg)

Information:

(1) Cylinder head bolts and nuts: 1. Put clean engine oil on the threads of bolts and nuts. Tighten bolts and nuts (cold), numbers 1 thru 32 in order shown, to a torque of 155 N m (115 lb.ft.)2. Tighten small bolts (cold), numbers 33 thru 38, to a torque of ... 38 N m (28 lb.ft.)Retighten the cylinder head bolts and nuts after the engine has run and the coolant temperature is no less than 77°C (170°F) as follows:a. If the bolts and nuts move before the correct torque (above) is reached, tighten the bolts and nuts (hot) to the torques that follow: No. 1 thru 32 ... 142 N m (105 lb.ft.)No. 33 thru 38 ... 38 N m (28 lb.ft.)b. If the bolts and nuts do not move before the correct torque is reached, back each one off 30 to 60° and retighten them again in the order shown to the torques shown in Step a. After all the bolts and nuts are retightened, check the first 10 positions again to make sure they are tightened to the correct torque.(2) Torque for nuts that hold injectors to cylinder head ... 17 N m (12 lb.ft.) Replace the copper washer and rubber seal between the head and the injector every time the injector is removed. (See Fuel Injector Installation in TESTING AND ADJUSTING.) Make sure the correct thickness washer is installed. They are as follows: 6.3544 Engines ... 2.03 mm (.080 in.)T6.3544 Engines ... 0.71 mm (.028 in.)(3) Torque for fuel line nuts ... 20 N m (15 lb.ft.)(4) Tighten rocker shaft assembly bolts and nuts from the center outward to a torque of ... 75 N m (55 lb.ft.)(5) Valve clearance (cold): Intake ... 0.20 mm (.008 in.)Exhaust ... 0.46 mm (.018 in.)(6) Maximum permissible injector nozzle projection below cylinder head face (with seating washers in position) after skimming: 6.3544 Engines ... 3.45 mm (.136 in.) max.T6.3544 Engines ... 4.67 mm (.184 in.) max.Skimming allowance ... 0.30 mm (.012 in.) max.(7) Depth of cylinder head (new) ... 94.87 to 95.63 mm (3.735 to 3.765 in.) Minimum depth of cylinder head (after skimming) ... 94.87 mm (3.735 in.)Maximum permissible amount of bow (curve of cylinder head): across width (transverse) ... 0.13 mm (.005 in.)across length (longitudinal) ... 0.25 mm (.010 in.)(See Cylinder Head Check in TESTING AND ADJUSTING)