106871-0842 ZEXEL 9 400 618 055 BOSCH INJECTION-PUMP ASSEMBLY 9400618055 1068710842 1671397762

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 055 9400618055

ZEXEL 106871-0842 1068710842

NISSAN-DIESEL 1671397762 1671397762

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Service parts 106871-0842 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-7560

3. GOVERNOR 105487-2204

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 105100-6800

11. Nozzle and Holder 1660097060

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

13. NOZZLE-HOLDER 105031-4210

14. NOZZLE 105015-6450

15. NOZZLE SET

Include in #1:

106871-0842 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 055 9400618055

ZEXEL 106871-0842 1068710842

NISSAN-DIESEL 1671397762 1671397762

Zexel num

Bosch num

Firm num

Name

106871-0842

9 400 618 055

1671397762 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 9.8

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 101.5 100.5 102.5

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.7

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 90.2 88.2 92.2

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 6.3+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 12.9 10.9 14.9

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)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)Damper spring setting (6)Excess fuel setting for starting
----------
RT=1 TH=1.9mm R1=10.5+-0.1mm
----------

Speed control lever angle

F:Full speed
----------

----------
a=13deg+-5deg

0000000901

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

----------
a=24.5deg+-5deg b=31.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Rack position bb (3)Drive side
----------
aa=32mm bb=10.5+-0.1mm
----------
a=1.5deg+-5deg b=27deg+-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:

Start By:a. remove oil pump 1. Check each connecting rod cap for its location on the crankshaft. Each cap must have a number (1) which is the same as the number on the connecting rod. Do not mix bearings.2. Turn the crankshaft until two of the pistons are at bottom center.3. Remove connecting rod caps (2). Remove the lower bearing from the connecting rod caps.4. Push the connecting rods away from the crankshaft and remove the upper bearings from the connecting rods.
Be careful not to damage the crankshaft journals. Do not turn the crankshaft while any of the connecting rod caps are removed.
5. Install the upper bearings in connecting rods. put clean engine oil on the bearings and on the crankshaft journals. Slowly pull the connecting rods on the crankshaft.6. Put clean oil on the lower bearings. Install the lower bearings in the connecting rod caps. Be sure tab (3) on the back of the bearings fits in the groove of the caps and connecting rods. 7. Check the bearing clearance with Plastigage (A) as follows:a. Put clean oil on the threads of bolts (4). Install caps (5), Tool (A) and nuts finger tight.b. Tighten each nut (6) to a torque of 80 8 N m (60 6 lb ft).c. Put a mark across the nuts and bolts. Tighten the nuts 120 degrees more. 8. Remove caps (5) and Plastigage (A). Make sure the connecting rod bearing caps are installed with their identification number in arrangement with the connecting rod number.
Do not use an impact wrench to tighten the nuts the additional 120 degrees.
9. Measure the thickness of the Plastigage to find the bearing clearance. the clearance for new bearings must be 0.071 to 0.168 mm (.0028 to .0066 in). The maximum clearance for used bearings is 0.25 mm (0.010 in).10. Install caps (5). Tighten nuts (6) to a torque of 80 8 N m (60 6 lb ft). Tighten the nuts 120 degrees more.11. Do Steps 1 through 10 for the other connecting rod bearings.End By:a. install oil pump