106971-0446 ZEXEL 9 400 618 625 BOSCH INJECTION-PUMP ASSEMBLY 9400618625 1069710446 1671397101

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 625 9400618625

ZEXEL 106971-0446 1069710446

NISSAN-DIESEL 1671397101 1671397101

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Service parts 106971-0446 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106097-5261

3. GOVERNOR 105487-2613

4. SUPPLY PUMP 105237-4190

5. AUTOM. ADVANCE MECHANIS 105636-2800

6. COUPLING PLATE 105662-1150

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7270

11. Nozzle and Holder 1660097066

12. Open Pre:MPa(Kqf/cm2) 14.7(150)/19.6(200)

13. NOZZLE-HOLDER 105031-4790

14. NOZZLE

105015-6930

15. NOZZLE SET

Include in #1:

106971-0446 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 625 9400618625

ZEXEL 106971-0446 1069710446

NISSAN-DIESEL 1671397101 1671397101

Zexel num

Bosch num

Firm num

Name

106971-0446

9 400 618 625

1671397101 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
RE10 * 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 10-9-4-3 -6-5-8-7 -2-1

Pre-stroke mm 3.65 3.6 3.7

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 10-9 deg. 45 44.5 45.5

Difference between angles 2
Cal 10-4 deg. 72 71.5 72.5

Difference between angles 3
Cal 10-3 deg. 117 116.5 117.5

Difference between angles 4
Cal 10-6 deg. 144 143.5 144.5

Difference between angles 5
Cal 10-5 deg. 189 188.5 189.5

Difference between angles 6
Cal 10-8 deg. 216 215.5 216.5

Difference between angles 7
Cal 10-7 deg. 261 260.5 261.5

Difference between angles 8
Cal 10-2 deg. 288 287.5 288.5

Difference between angles 9
Cal 10-1 deg. 333 332.5 333.5

Injection quantity adjustment

Adjusting point A

Rack position 9.3

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 111.5 110.5 112.5

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.5

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 105.2 103.2 107.2

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point E

Rack position 6.3+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 9.4 7.4 11.4

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 950

Advance angle deg. 2.2 1.7 2.7

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 stop lever: R1 (at N = N1 or less). (2)Excess fuel setting for starting: SXL (3)Damper spring setting: DL
----------
R1=13.8+0.2mm N1=100r/min SXL=10.1+-0.1mm DL=5.8-0.2mm
----------

Speed control lever angle

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

----------
a=7deg+-5deg

0000000901

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

----------
a=18.5deg+-5deg b=29.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Use the hole at R = bb
----------
aa=13.8+0.2mm bb=32mm
----------
a=36deg+-5deg b=10.5deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of the coupling's key groove at the start of injection for the No. 10 cylinder. (3)- (4)-
----------

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

Information:

Measure wear of the cylinder bore at the top and bottom of piston ring travel.(1) Cylinder bore [standard, original size] ... 4.5005 .0005 in.(114.313 0.013 mm) The recommendation is made to make the cylinder bore the next size larger when the size of the bore is ... 4.5060 in.(114.452 mm)Cylinder bore must be made the next size larger when the size of the bore is ... 4.5090 in.(114.529 mm)Cylinder bore [.020 in. (0.51 mm) larger than the original size] ... 4.5205 .0005 in.(114.821 0.013 mm)The recommendation is made to make the cylinder bore the next size larger when the size of the bore is ... 4.5260 in.(114.960 mm)Cylinder bore must be made the next size larger when the size of the bore is ... 4.5290 in.(115.037 mm)Cylinder bore [.040 in. (1.02 mm) larger than the original size] ... 4.5405 .0005 in.(115.329 0.013 mm)Maximum permissible wear of cylinder bores (replacement of the cylinder block is necessary) ... 4.5490 in.(115.545 mm)(2) Bore in block for camshaft bearing ... 2.6525 .0005 in.(67.374 0.013 mm)(3) Width of main bearing cap ... 6.5600 .0005 in.(116.624 0.013 mm) Minimum permissible width of main bearing cap ... 6.5580 in.(116.573 mm)Width of main bearing cap guide (in cylinder block) ... 6.5590 .0005 in.(116.599 0.013 mm)(4) Bore in block for main bearing ... 3.7075 .0005 in.(94.171 0.013 mm) Permissible amount of distortion in bore ... 3.706 to 3.709 in.(94.13 to 94.21 mm)(5) Torque for bolts holding caps for main bearings: A. Put crankcase oil on bolt threads and washer face.B. Tighten all bolts by number to ... 60 15 lb. ft.(8.3 2.0 mkg)C. Again tighten all bolts by number to ... 175 10 lb. ft.(24.2 1.4 mkg)Engines with Serial Numbers 98M2494 and Up, tighten bolts (5) holding caps for main bearings in the following sequence: 1. Put crankcase oil on bolt threads and washer face.2. Tighten all bolts by number to ... 30 3 lb. ft.(4.1 0.4 mkg)3. Put a mark on each bolt and cap.4. Tighten all bolts by number from mark ... 120° 5°