106873-7722 ZEXEL 9 400 618 511 BOSCH INJECTION-PUMP ASSEMBLY 9400618511 1068737722 me163507

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 511 9400618511

ZEXEL 106873-7722 1068737722

MITSUBISHI ME163507 me163507

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Service parts 106873-7722 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106080-7091

3. GOVERNOR 105923-2992

4. SUPPLY PUMP 105237-5660

5. AUTOM. ADVANCE MECHANIS 105691-4040

6. COUPLING PLATE 105664-2020

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-7391

11. Nozzle and Holder ME161933

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/24.5{250}

13. NOZZLE-HOLDER 105041-4101

14. NOZZLE

15. NOZZLE SET 105019-0380

Include in #1:

106873-7722 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 511 9400618511

ZEXEL 106873-7722 1068737722

MITSUBISHI ME163507 me163507

Zexel num

Bosch num

Firm num

Name

106873-7722

9 400 618 511

ME163507 MITSUBISHI

INJECTION-PUMP ASSEMBLY
8M20 K 14CD INJECTION PUMP ASSY PE8P PE

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8250

Bosch type code 1 688 901 101

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 20.7

Opening pressure kgf/cm2 211

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600

Overflow valve 131425-0220

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-2-7-3- 4-5-6-8

Pre-stroke mm 3.9 3.85 3.95

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cyl.1-2 deg. 45 44.5 45.5

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

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

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

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

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

Difference between angles 7
Cal 1-8 deg. 315 314.5 315.5

Injection quantity adjustment

Adjusting point -

Rack position 12.7

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 144 139.7 148.3

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 8+-0.5

Pump speed r/min 445 445 445

Each cylinder's injection qty mm3/st. 16.5 14 19

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.7)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 144 143 145

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.8

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 139 135 143

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position (R1-0.8)

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 139.5 135.5 143.5

Fixing the lever *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Damper spring setting
----------
T1=AD95
----------

Timer adjustment

(1)Adjusting range (2)Step response time (N): Speed of the pump (L): Load (theta) Advance angle (Srd1) Step response time 1 (Srd2) Step response time 2 1. Adjusting conditions for the variable timer (1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1-0.2mm N2=800r/min C2=(10)deg t1=2.5--sec. t2=2.5--sec.
----------
N1=750++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=10+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H' (3)Viewed from feed pump side.
----------
aa=37.5mm
----------
a=30deg+-5deg b=(37deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the stopper bolt so that speed = bb and rack position = cc. (Confirm non-injection.) (3)Normal engine position (equivalent to R = dd).
----------
aa=54mm bb=1100r/min cc=3.5+-0.3mm dd=18mm
----------
a=41deg+-5deg b=5.5deg+-5deg c=(31deg)

0000001501 RACK SENSOR

(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack sensor adjustment (-0620) (1)Fix the speed control lever at the full position (2)Set the speed to N1 r/min. (If the boost compensator is provided, apply boost pressure.) (3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01. (4)At that time, rack position must be Ra. (5)Apply G at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the joint (B) and the end surface of the pump (H)
----------
N1=1100r/min Ra=R1+0.8mm
----------

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=6deg
----------
a=(50deg)

Information:

(1) Bore in rocker arm for shaft ... 24.803 0.013 mm (.9765 .0005 in) Diameter of rocker arm shaft ... 24.752 0.013 mm (.9745 .0005 in)(2) Put 5P3931 Anti-Seize Compound on all the threads of bolts that hold rocker arm shafts and tighten the bolts in the step sequence that follows:Step 1. Tighten bolts from 1 through 6 in number sequence to ... 270 27 N m (200 20 lb ft)Step 2. Tighten bolts from 1 through 6 in number sequence to ... 450 20 N m (330 15 lb ft)Step 3. Tighten bolts from 1 through 6 in number sequence again to ... 450 20 N m (330 15 lb ft) (3) Torque for locknut for valve adjustment screw ... 30 4 N m (22 3 lb ft)(4) Torque for locknut for bridge assembly ... 30 4 N m (22 3 lb ft)Bridge Installation Instructions:a. Lubricate bridge dowel, bridge bore and top pad of bridge with engine oil.b. Install bridge assembly on bridge dowel.c. While firmly pressing [0.5 to 4.5 kg (1 to 10 lb)] straight down on the bridge pad, turn the adjusting screw clockwise until contact is made with the valve stem.d. Turn the screw clockwise and additional 20 to 30° (1/3 to 1/2 of 1 hex on nut) to straighten the dowel in the guide and compensate for slack in the threads.e. Hold the adjusting screw in this position and tighten the locknut to a torque of 30 4 N m (22 3 lb ft).(5) Valve clearance (with engine stopped). Intake valves ... 0.38 mm (.015 in)Exhaust valves ... 0.76 mm (.030 in) After setting valve clearance, tighten adjusting screw locknut to a torque of 30 4 N m (22 3 lb ft). Then, recheck the valve clearance.(5) Clearance for valves: Intake valves ... 0.38 mm (.015 in)Exhaust valves ... 0.76 mm (.030 in)(6) Height to top of dowel ... 53.3 0.5 mm (2.10 .02 in)(7) Diameter of dowel ... 11.008 0.003 mm (.4334 .0001 in) Bore in bridge for dowel ... 11.13 0.05 mm (.438 .002 in)Bore in head for dowel ... 10.968 0.020 mm (.4318 .0008 in) (8) Diameter of valve lifter ... 27.896 0.013 mm (1.0983 .0005 in) Bore in block for valve lifter ... 27.953 0.019 mm (1.1005 .0008 in) See Guideline For Reusable Parts; Salvage Of Lifter Bores In 3400 Family Engines, Form No. SEBF8069 for the procedure, tooling and specifications needed to install 4W4588 Sleeves for salvage of the lifter bores in the cylinder block.(9) 6N6872 Lifter Guide Spring. See Guideline For Reusable Parts, Form No. SEBF8066, for information on using guide springs again. (10) 2N7229 Spring: Length under test force ... 74.2 mm (2.92 in)Test force ... 45 to 53 N (10 to 12 lb)Free length after test ... 114.3 mm (4.50 in)Outside