101608-6400 ZEXEL 9 400 613 004 BOSCH INJECTION-PUMP ASSEMBLY 9400613004 1016086400


 

Information injection-pump assembly

BOSCH 9 400 613 004 9400613004
ZEXEL 101608-6400 1016086400
101608-6400 INJECTION-PUMP ASSEMBLY
Rating:
36
Buy INJECTION-PUMP ASSEMBLY 101608-6400 zexel genuine, new aftermarket engine parts with delivery

Service parts 101608-6400 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-6800
3. GOVERNOR 105411-2460
4. SUPPLY PUMP 105210-5450
5. AUTOM. ADVANCE MECHANIS 105680-9030
6. COUPLING PLATE 105663-1150
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105160-5190
11. Nozzle and Holder ME440071
12. Open Pre:MPa(Kqf/cm2) 17.7{180}
13. NOZZLE-HOLDER 105030-3660
14. NOZZLE 105025-3250
15. NOZZLE SET

Include in #1:

101608-6400 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 613 004 9400613004
ZEXEL 101608-6400 1016086400


Zexel num
Bosch num
Firm num
Name
101608-6400 
101608-6401 
9 400 613 004 
   
INJECTION-PUMP ASSEMBLY
* 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   6-2-600
Overflow valve   131424-5520
Overflow valve opening pressure kPa   255 221 289
Overflow valve opening pressure kgf/cm2   2.6 2.25 2.95
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)
Left
  L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left
  L
Injection order   1-5-3-6- 2-4
Pre-stroke mm   4.5 4.45 4.55
Beginning of injection position
Governor side
  NO.1
Difference between angles 1
Cal 1-5
deg.   60 59.5 60.5
Difference between angles 2
Cal 1-3
deg.   120 119.5 120.5
Difference between angles 3
Cal 1-6
deg.   180 179.5 180.5
Difference between angles 4
Cyl.1-2
deg.   240 239.5 240.5
Difference between angles 5
Cal 1-4
deg.   300 299.5 300.5
Injection quantity adjustment
Adjusting point   A
Rack position   11
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   109.5 108.5 110.5
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the lever   *
Boost pressure kPa   62.7 62.7
Boost pressure mmHg   470 470
Injection quantity adjustment_02
Adjusting point   -
Rack position   8+-0.5
Pump speed r/min   400 400 400
Average injection quantity mm3/st.   16.5 15 18
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Injection quantity adjustment_03
Adjusting point   E
Rack position   11.2++
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   95 95 105
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Rack limit   *
Boost compensator adjustment
Pump speed r/min   375 375 375
Rack position   9.2
Boost pressure kPa   10.7 4 17.4
Boost pressure mmHg   80 30 130
Boost compensator adjustment_02
Pump speed r/min   375 375 375
Rack position   10.45
Boost pressure kPa   56 50.6 56
Boost pressure mmHg   420 380 420
Timer adjustment
Pump speed r/min   600
Advance angle deg.   3 2.5 3.5
Load   0/4
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   720
Advance angle deg.   0.5
Load   0/4
Timer adjustment_03
Pump speed r/min   (850)
Advance angle deg.   0 0 0
Load   4/4
Remarks
Measure the actual speed.
 
Timer adjustment_04
Pump speed r/min   1075
Advance angle deg.   1.5 1 2
Load   4/4
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101608-6400
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Boost compensator stroke: BCL (5)Main spring setting (6)Set idle sub-spring
----------
K=10 BCL=1.25+-0.1mm
----------

Speed control lever angle

Test data 101608-6400
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=18deg+-5deg b=0deg+-5deg

Stop lever angle

Test data 101608-6400
N:Pump normal S:Stop the pump. (1)Normal (2)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.5mm
----------
a=35deg+-5deg b=(55deg)

0000001501 TAMPER PROOF

Test data 101608-6400
Tamperproofing-equipped boost compensator cover installation procedure (A) After adjusting the boost compensator, tighten the bolts to remove the heads. (1)Before adjusting the governor and the boost compensator, tighten the screw to the specified torque. (Tightening torque T = T1 maximum) (2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T2 maximum)
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
----------

0000001601 RACK SENSOR

Test data 101608-6400
(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack limit adjustment (1)Mount the joint (B). (2)Select the shim (D) so that the rack limit's rack position is obtained at that time. (3)Install the rod (E) to the block (C). The distance between the pump end face and the rod (E) at rack limit must be L. 2. Rack sensor adjustment (-0020) (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the speed control lever at the full side. (3)Set at speed N. (4)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR+-0.01 (V), then tighten the nut (F). (If equipped with a boost compensator, perform with boost pressure applied.) (5)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01. (6)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)
----------
L=38-0.2mm N=1000r/min Ra=11mm
----------

Timing setting

Test data 101608-6400
(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=8deg
----------
a=(3deg)




Information:

The front plate is bolted inside the timing gear case. Do not attempt to remove this plate along with the timing gear case by tapping.
Front plate attaching bolts8. Timing gear backlash measurement Measure the backlash of each gear and keep a record of it for correct installation. Replace the gears if the backlash exceeds the limit.
Unit: mm (in.)
Measuring timing gear backlash9. Idler gear removal To remove the idler gear, rotate the gear in a direction of the helix of the teeth to pull it out of mesh.
Removing idler gear10. Camshaft removal (1) Remove the bolts that hold the thrust plate. (2) Pull the camshaft out of the cylinder block.
Do not cause damage to the lobes or bearing journals when removing the camshaft.
Removing camshaft11. Fuel injection pump camshaft removal(1) Remove the stopper bolt.
Removing camshaft stopper bolt(2) Tap the rear end of the camshaft with a copper bar to push it out of the front side of the cylinder block.
Removing fuel injection pump camshaft12. Gear removal (when required) To remove the gears from the camshaft and fuel injection pump camshaft, use an arbor press.13. Oil pump removal Remove the bolts that hold the oil pump to the cylinder block and remove the pump.
Removing oil pump14. Front plate removal Remove four bolts that hold the front plate in position. Tap the plate lightly with a plastic hammer to separate the gasket.
Removing front plateCYLINDER BLOCK, CRANKSHAFT, PISTONS AND OIL PAN
1 Oil pan2 Oil screen3 Connecting rod cap4 Connecting rod bearing (lower half) (Remove 5 thru 10 as an assembly.)5 Connecting rod6 Piston pin7 No. 1 ring8 No. 2 ring9 Oil ring10 Piston11 Connecting rod bearing (upper half)12 Main bearing cap13 Main bearing (lower half)14 Crankshaft15 Main bearing (upper half)16 Cylinder block When the cylinder block is to be discarded, remove the components (pressure relief valve, etc.) from the block for reuse. 1. Oil pan removal (1) Turn the engine upside down.(2) Tap the bottom corners of the oil pan with a plastic hammer to remove the oil pan.
Do not attempt to pry off the oil pan by inserting a screwdriver or a chisel between the oil pan and cylinder block. Damage to the oil pan can be the result.
Removing oil pan2. Oil screen removal Loosen the nut that holds the oil screen in position and remove the screen.
Removing oil screen3. Thrust clearance measurement for connecting rod big endInstall the connecting rod to its crankpin and tighten the cap nuts to the specified torque. Measure the thrust clearance with a feeler gauge. If the clearance exceeds the limit, replace the connecting rod.
Measuring thrust clearance for connecting rod big end
Unit: mm (in.)4. Connecting rod cap removal (1) Lay the cylinder block on its side.(2) Put identification on each connecting rod and cap combination as to its location in the engine.(3) Remove the caps.
Removing connecting rod caps5. Piston removal (1) Turn the crankshaft until the piston is at top center. (2) Push the piston and connecting rod away from the crankshaft with the handle of

Have questions with 101608-6400?





Group cross 101608-6400 ZEXEL

101608-6400  

101608-6401 
9 400 613 004 
 
INJECTION-PUMP ASSEMBLY
9 400 615 853 
 
INJECTION-PUMP ASSEMBLY

Mitsubishi 

9 400 619 940 
ME441213 
INJECTION-PUMP ASSEMBLY
6D16TL
9 400 619 508 
 
INJECTION-PUMP ASSEMBLY
9 400 619 509 
 
INJECTION-PUMP ASSEMBLY

Mitsubishi 

9 400 615 854 
ME441215 
INJECTION-PUMP ASSEMBLY
6D34TL
9 400 619 510 
 
INJECTION-PUMP ASSEMBLY
9 400 619 511 
 
INJECTION-PUMP ASSEMBLY

Mitsubishi 

9 400 615 855 
ME441232 
INJECTION-PUMP ASSEMBLY
6D34TL
9 400 613 005 
 
INJECTION-PUMP ASSEMBLY
9 400 619 512 
 
INJECTION-PUMP ASSEMBLY

Mitsubishi 

9 400 613 472 
ME441260 
INJECTION-PUMP ASSEMBLY
6D16TL
9 400 612 753 
 
INJECTION-PUMP ASSEMBLY
9 400 612 921 
 
INJECTION-PUMP ASSEMBLY
9 400 613 106 
 
INJECTION-PUMP ASSEMBLY
F 019 Z10 296 
 
INJECTION-PUMP ASSEMBLY
6D34TL

Mitsubishi 

F 019 Z10 296 
ME441273 
INJECTION-PUMP ASSEMBLY
6D34TL
F 019 Z10 904 
ME441273 
INJECTION-PUMP ASSEMBLY
6D34TL
9 400 619 513 
 
INJECTION-PUMP ASSEMBLY
9 400 613 262 
 
INJECTION-PUMP ASSEMBLY
9 400 613 295 
 
INJECTION-PUMP ASSEMBLY
9 400 613 380 
 
INJECTION-PUMP ASSEMBLY
 
 
INJECTION-PUMP ASSEMBLY

Mitsubishi 

F 019 Z20 023 
ME441286 
INJECTION-PUMP ASSEMBLY
6D16TL
9 400 613 329 
 
INJECTION-PUMP ASSEMBLY
9 400 615 856 
 
INJECTION-PUMP ASSEMBLY

Mitsubishi 

F 019 Z20 024 
ME441276 
INJECTION-PUMP ASSEMBLY
6D16TL
9 400 619 514 
 
INJECTION-PUMP ASSEMBLY

Mitsubishi 

9 400 613 381 
ME441278 
INJECTION-PUMP ASSEMBLY
6D34TL
9 400 619 515 
 
INJECTION-PUMP ASSEMBLY
9 400 619 431 
 
INJECTION-PUMP ASSEMBLY
9 400 613 382 
 
INJECTION-PUMP ASSEMBLY

Mitsubishi 

F 019 Z20 025 
ME441450 
INJECTION-PUMP ASSEMBLY
6D16TL
9 400 619 516 
 
INJECTION-PUMP ASSEMBLY
9 400 613 383 
 
INJECTION-PUMP ASSEMBLY

Mitsubishi 

F 019 Z20 026 
ME441451 
INJECTION-PUMP ASSEMBLY
6D16TL
Back to top