104700-9153 ZEXEL 9 460 614 964 BOSCH INJECTION-PUMP ASSEMBLY


Information injection-pump assembly

BOSCH 9 460 614 964 9460614964
ZEXEL 104700-9153 1047009153

Components :

0. INJECTION-PUMP ASSEMBLY 104700-9153
1. _
2. FUEL INJECTION PUMP
3. NUMBER PLATE 148643-3400
4. _
5. CAPSULE
6. ADJUSTING DEVICE
7. NOZZLE AND HOLDER ASSY
8. Nozzle and Holder
9. Open Pre:MPa(Kqf/cm2)
10. NOZZLE-HOLDER
11. NOZZLE

Scheme #3:

1/6. [1] 146601-0700 PACKING RING
6. [1] 146100-0120 SUPPLY PUMP
9. [1] 148103-0400 COVER
10. [2] 139104-0000 FLAT-HEAD SCREW
12. [1] 148200-0520 DRIVE SHAFT
17. [1] 146204-0000 PLAIN WASHER
20. [1] 148210-0120 ROLLER SET
24. [1] 146303-0000 BEARING PIN
25. [1] 146304-0000 BEARING PIN
26. [1] 146305-0000 CLAMPING BAND
27. [1] 146205-0000 SLOTTED WASHER
29. [1] 146220-2120 CAM PLATE
30. [1] 146600-0800 O-RING
31. [1] 146300-1900 PUMP PLUNGER
32. [1] 146301-0000 SLIDING PIECE
33. [1] 146603-1100 SHIM
34. [1] 146306-1800 COMPRESSION SPRING
34B. [1] 146306-2100 COMPRESSION SPRING
35/1. [0] 146603-0700 SHIM
35/1. [0] 146603-0800 SHIM
35/1. [0] 146603-0900 SHIM
35/1. [0] 146603-1000 SHIM
35/1. [0] 146603-1100 SHIM
35/1. [0] 146603-3600 SHIM
36. [1] 146600-0800 O-RING
37. [1] 479766-3820 TIMER PISTON SENSOR
38. [2] 146622-1200 HEX-SOCKET-HEAD CAP SCREW
39. [1] 146310-5600 COVER
40. [2] 146622-1300 BLEEDER SCREW
43. [1] 146230-0000 SHIM
44. [1] 146230-0100 PLAIN WASHER
45. [1] 146231-0001 SLOTTED WASHER
47. [2] 146233-0000 SLOTTED WASHER
48/1. [1] 146603-0000 SHIM
48/1. [1] 146603-0100 SHIM
48/1. [1] 146603-0200 SHIM
48/1. [1] 146603-0300 SHIM
48/1. [1] 146603-0400 SHIM
48/1. [1] 146603-0500 SHIM
48/1. [1] 146603-0600 SHIM
48/1. [1] 146690-1400 SHIM
48/1. [1] 146690-1500 SHIM
48/1. [1] 146690-1600 SHIM
48/1. [1] 146690-1700 SHIM
48/1. [1] 146690-1800 SHIM
48/1. [1] 146690-1900 SHIM
48/1. [1] 146690-5800 SHIM
48/1. [1] 146690-5900 SHIM
48/1. [1] 146690-6000 SHIM
48/1. [1] 146690-6100 SHIM
48/1. [1] 146690-6200 SHIM
48/1. [1] 146690-6300 SHIM
48/1. [1] 146690-6400 SHIM
48/1. [1] 146690-6500 SHIM
48/1. [1] 146690-6600 SHIM
48/1. [1] 146690-6700 SHIM
48/1. [1] 146690-6800 SHIM
48/1. [1] 146690-6900 SHIM
48/1. [1] 146690-7000 SHIM
48/1. [1] 146690-7100 SHIM
48/1. [1] 146690-7200 SHIM
48/1. [1] 146690-7300 SHIM
48/1. [1] 146690-7400 SHIM
48/1. [1] 146690-7500 SHIM
48/1. [1] 146690-7800 SHIM
49. [2] 146234-0500 GUIDE PIN
50. [1] 146403-9620 HYDRAULIC HEAD
50. [1] 146403-9620 HYDRAULIC HEAD
50. [1] 146403-9620 HYDRAULIC HEAD
51. [1] 146600-0000 O-RING
52/1. [1] 146420-0000 SHIM
52/1. [1] 146420-0100 SHIM
52/1. [1] 146420-0200 SHIM
52/1. [1] 146420-0300 SHIM
52/1. [1] 146420-0400 SHIM
52/1. [1] 146420-0500 SHIM
52/1. [1] 146420-0600 SHIM
52/1. [1] 146420-0700 SHIM
52/1. [1] 146420-0800 SHIM
52/1. [1] 146420-0900 SHIM
52/1. [1] 146420-1000 SHIM
52/1. [1] 146420-1100 SHIM
52/1. [1] 146420-1200 SHIM
52/1. [1] 146420-1300 SHIM
52/1. [1] 146420-1400 SHIM
52/1. [1] 146420-1500 SHIM
52/1. [1] 146420-1600 SHIM
52/1. [1] 146420-1700 SHIM
52/1. [1] 146420-1800 SHIM
52/1. [1] 146420-1900 SHIM
52/1. [1] 146420-2000 SHIM
52/1. [1] 146420-2100 SHIM
52/1. [1] 146420-2200 SHIM
52/1. [1] 146420-2300 SHIM
52/1. [1] 146420-2400 SHIM
52/1. [1] 146420-2500 SHIM
52/1. [1] 146420-2600 SHIM
52/1. [1] 146420-2700 SHIM
52/1. [1] 146420-2800 SHIM
52/1. [1] 146420-2900 SHIM
52/1. [1] 146420-3000 SHIM
52/1. [1] 146420-3100 SHIM
52/1. [1] 146420-3200 SHIM
52/1. [1] 146420-3300 SHIM
52/1. [1] 146420-3400 SHIM
52/1. [1] 146420-3500 SHIM
52/1. [1] 146420-3600 SHIM
52/1. [1] 146420-3700 SHIM
52/1. [1] 146420-3800 SHIM
52/1. [1] 146420-3900 SHIM
52/1. [1] 146420-4000 SHIM
52/1. [1] 146420-4100 SHIM
52/1. [1] 146420-4200 SHIM
52/1. [1] 146420-4300 SHIM
52/1. [1] 146420-4400 SHIM
52/1. [1] 146420-4500 SHIM
52/1. [1] 146420-4600 SHIM
52/1. [1] 146420-4700 SHIM
52/1. [1] 146420-4800 SHIM
52/1. [1] 146420-4900 SHIM
52/1. [1] 146420-5000 SHIM
52/1. [1] 146420-5100 SHIM
52/1. [1] 146420-5200 SHIM
52/1. [1] 146420-5300 SHIM
52/1. [1] 146420-5400 SHIM
52/1. [1] 146420-5500 SHIM
52/1. [1] 146420-5600 SHIM
52/1. [1] 146420-5700 SHIM
52/1. [1] 146420-5800 SHIM
54. [4] 146433-0100 GASKET
55. [4] 146430-0320 DELIVERY-VALVE ASSEMBLY
56. [4] 146432-0000 COMPRESSION SPRING
58. [4] 146440-3220 FITTING
60. [3] 146622-1800 FLAT-HEAD SCREW
123. [1] 146622-0900 FLAT-HEAD SCREW
130. [1] 146421-1920 CAPSULE
130/2. [1] 139508-0200 GASKET
130/3. [1] 146422-0700 BLEEDER SCREW
130/4. [1] 146600-0500 O-RING
133. [1] 146600-0600 O-RING
134. [1] 146600-0700 O-RING
135. [1] 146110-3520 CONTROL VALVE
135/5. [1] 146114-0000 SPRING WASHER
136. [1] 148120-0320 OVER FLOW VALVE
137. [3] 139512-0500 GASKET
138. [1] 146669-5821 INLET UNION
158. [1] 146663-5500 SPACER BUSHING
200. [1] 146206-0100 COILED SPRING
205. [1] 029470-4030 WOODRUFF KEY
230. [1] 148613-6620 BRACKET
236. [1] 146622-1400 HEX-SOCKET-HEAD CAP SCREW
237. [1] 146622-1500 HEX-SOCKET-HEAD CAP SCREW
240. [1] 146688-3720 PULLING ELECTROMAGNET
240/8. [1] 146600-1700 O-RING
243. [1] 146621-1000 UNION NUT
245. [3] 139512-0500 GASKET
246. [1] 146125-1000 EYE BOLT
247. [1] 146677-7920 INLET UNION
248. [1] 146663-5600 SPACER BUSHING
275. [1] 148612-1600 BRACKET
276. [2] 146622-1700 BLEEDER SCREW
278. [2] 146663-5700 SPACER BUSHING
282. [1] 146622-1900 BLEEDER SCREW
504/1. [1] 146649-4500 RESISTER
504/1. [1] 146649-4600 RESISTER
504/1. [1] 146649-4700 RESISTER
504/1. [1] 146649-4800 RESISTER
504/1. [1] 146649-4900 RESISTER
504/1. [1] 146649-5000 RESISTER
504/1. [1] 146649-5100 RESISTER
504/1. [1] 146649-5200 RESISTER
504/1. [1] 146649-5300 RESISTER
504/1. [1] 146649-5400 RESISTER
504/1. [1] 146649-5500 RESISTER
504/1. [1] 146649-5600 RESISTER
504/1. [1] 146649-5700 RESISTER
505. [1] 148530-4820 GOVERNOR;ELECTRIC
506. [3] 146622-1000 FLAT-HEAD SCREW
515. [1] 106144-1071 TIMING CONTROL VALVE
515/7. [1] 161440-3800 O-RING
515/8. [1] 161440-3700 O-RING
516. [2] 146622-1600 HEX-SOCKET-HEAD CAP SCREW
531. [1] 479766-3620 PULSE GENERATOR
531/6. [1] 479773-6500 O-RING
535. [1] 148650-0300 TAPE
536. [1] 148650-4100 TUBE
551. [1] 146659-9501 CLAMPING BAND
552. [1] 014110-8442 LOCKING WASHER
553. [1] 010208-1242 HEX-SOCKET-HEAD CAP SCREW
800S. [1] 148009-0620 PUMP HOUSING
800S/1/6. [1] 146601-0700 PACKING RING
804S. [1] 146232-0320 COMPRESSION SPRING
810S. [1] 146600-4620 REPAIR SET
821S. [1] 146210-5720 ROLLER SET
878S. [1] 148600-1300 SEAL RING
906. [1] 148643-3400 NAMEPLATE

Include in #2:

104700-9153 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 460 614 964 9460614964
ZEXEL 104700-9153 1047009153


Zexel num Bosch num Firm num Firm Name
104700-9153  9 460 614 964      INJECTION-PUMP ASSEMBLY
4D56TCI 11CL INJECTION PUMP ASSY COVEC 4 COVEC
104700-9153 
104700-9154 
9 460 614 964  3310542720  HYUNDAI INJECTION-PUMP ASSEMBLY
4D56TCI * K 11CL INJECTION PUMP ASSY COVEC 4 COVEC

Calibration Data:



Adjustment conditions
Test oil   ISO4113orSAEJ967d
1404 Test oil
Test oil temperature degC   45 45 50
Nozzle   105780-0060
Bosch type code   NP-DN0SD1510
Nozzle holder   105780-2150
Opening pressure MPa   13 13 13.3
Opening pressure kgf/cm2   133 133 136
Injection pipe   157805-7320
Injection pipe mm   2-6-450
Inside diameter - outside diameter - length (mm)
Joint assembly   157641-4720
Tube assembly   157641-4020
Transfer pump pressure kPa   20 20 20
Transfer pump pressure kgf/cm2   0.2 0.2 0.2
Direction of rotation (viewed from drive side)   R
Right


Governor adjustment
Pump speed r/min   1000 1000 1000
TCV duty (%) F TCV 60Hz %   100 100 100
U alpha soll V   2.7 2.7 2.7
Pump chamber pressure kPa   598 569 627
Pump chamber pressure kgf/cm2   6.1 5.8 6.4
Basic   *


Governor adjustment_02
Pump speed r/min   100 100 100
TCV duty (%) F TCV 60Hz %   100 100 100
U alpha soll V   2.7 2.7 2.7
Pump chamber pressure kPa   294 294
Pump chamber pressure kgf/cm2   3 3


Governor adjustment_03
Pump speed r/min   1000 1000 1000
TCV duty (%) F TCV 60Hz %   100 100 100
U alpha soll V   2.7 2.7 2.7
Pump chamber pressure kPa   598 559 637
Pump chamber pressure kgf/cm2   6.1 5.7 6.5


Governor adjustment_04
Pump speed r/min   2000 2000 2000
TCV duty (%) F TCV 60Hz %   100 100 100
U alpha soll V   2.7 2.7 2.7
Pump chamber pressure kPa   735 686 784
Pump chamber pressure kgf/cm2   7.5 7 8


Boost compensator adjustment
Pump speed r/min   1000 1000 1000
TCV duty (%) F TCV 60Hz %   100 100 100
U alpha soll V   2.7 2.7 2.7
Timer stroke mm   7.7 7.5 7.9
Basic   *


Boost compensator adjustment_02
Pump speed r/min   100 100 100
TCV duty (%) F TCV 60Hz %   100 100 100
U alpha soll V   2.7 2.7 2.7
Timer stroke mm   1.8 0.3 3.3


Boost compensator adjustment_03
Pump speed r/min   350 350 350
TCV duty (%) F TCV 60Hz %   100 100 100
U alpha soll V   2.7 2.7 2.7
Timer stroke mm   5.2 3.1 7.3


Boost compensator adjustment_04
Pump speed r/min   1000 1000 1000
TCV duty (%) F TCV 60Hz %   100 100 100
U alpha soll V   2.7 2.7 2.7
Timer stroke mm   7.7 7.4 8


Boost compensator adjustment_05
Pump speed r/min   1000 1000 1000
TCV duty (%) F TCV 60Hz %   70 70 70
U alpha soll V   2.7 2.7 2.7
Timer stroke mm   4 1.9 6.1


Boost compensator adjustment_06
Pump speed r/min   2000 2000 2000
TCV duty (%) F TCV 60Hz %   100 100 100
U alpha soll V   2.7 2.7 2.7
Timer stroke mm   9.75 9.3 10.2


Boost compensator adjustment_07
Pump speed r/min   2000 2000 2000
TCV duty (%) F TCV 60Hz %   0 0 0
U alpha soll V   2.7 2.7 2.7
Timer stroke mm   0 0 0


Timer adjustment
Pump speed r/min   1000 1000 1000
TCV duty (%) F TCV 60Hz %   0 0 0
U alpha soll V   2.7 2.7 2.7
Vtps V   0.51 0.382 0.638
Basic   *


Timer adjustment_02
Pump speed r/min   1000 1000 1000
TCV duty (%) F TCV 60Hz %   0 0 0
U alpha soll V   2.7 2.7 2.7
Vtps V   0.51 0.382 0.638


Timer adjustment_03
Pump speed r/min   1000 1000 1000
TCV duty (%) F TCV 60Hz %   100 100 100
U alpha soll V   2.7 2.7 2.7
Vtps V   1.925 1.702 2.148


Speed control lever angle
Pump speed r/min   1000 1000 1000
TCV duty (%) F TCV 60Hz %   100 100 100
U alpha soll V   2.7 2.7 2.7
Overflow quantity cm3/min   550 420 680


0000000901
Pump speed r/min   1250 1250 1250
U alpha soll + dU alpha soll V   2.86 2.86 2.86
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   72 71.5 72.5
Difference in delivery mm3/st.   3.5
Basic   *


_02
Pump speed r/min   375 375 375
U alpha soll + dU alpha soll V   2 2 2
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   14.8 11.8 17.8
Difference in delivery mm3/st.   2.5
Basic   *
Remarks  
Confirmation of difference in delivery


_03
Pump speed r/min   2575 2575 2575
U alpha soll + dU alpha soll V   1.96 1.96 1.96
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   20.3 17.8 22.8
Difference in delivery mm3/st.   5.5
Basic   *
Remarks  
Confirmation of difference in delivery


_04
Pump speed r/min   100 100 100
U alpha soll + dU alpha soll V   3.31 3.31 3.31
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   67.9 57.9 77.9


_05
Pump speed r/min   375 375 375
U alpha soll + dU alpha soll V   2 2 2
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   14.8 11.8 17.8


_06
Pump speed r/min   500 500 500
U alpha soll + dU alpha soll V   2.74 2.74 2.74
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   51.2 48.7 53.7


_07
Pump speed r/min   750 750 750
U alpha soll + dU alpha soll V   2.83 2.83 2.83
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   63.1 60.6 65.6


_08
Pump speed r/min   1000 1000 1000
U alpha soll + dU alpha soll V   2.87 2.87 2.87
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   70.4 67.9 72.9


_09
Pump speed r/min   1250 1250 1250
U alpha soll + dU alpha soll V   2.86 2.86 2.86
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   72 71 73


_10
Pump speed r/min   1500 1500 1500
U alpha soll + dU alpha soll V   2.82 2.82 2.82
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   68.6 66.1 71.1


_11
Pump speed r/min   1750 1750 1750
U alpha soll + dU alpha soll V   2.8 2.8 2.8
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   65.5 63 68


_12
Pump speed r/min   1900 1900 1900
U alpha soll + dU alpha soll V   2.77 2.77 2.77
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   63.8 61.3 66.3


_13
Pump speed r/min   2575 2575 2575
U alpha soll + dU alpha soll V   1.96 1.96 1.96
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   20.3 17.8 22.8


_14
Pump speed r/min   2575 2575 2575
U alpha soll + dU alpha soll V   1 1 1
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   3


Stop lever angle
Pump speed r/min   1900 1900 1900
U alpha soll + dU alpha soll V   2.77 2.77 2.77
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity cm3/min   0 0 0


0000001101
Pump speed r/min   200 200 200
TCV duty (%) F TCV 60Hz %   100 100 100
U alpha soll V   2.7 2.7 2.7
Speed output r/min   N+-8
N=Measure the actual speed.


0000001201
Pump speed r/min   1250 1250 1250
TCV duty (%) F TCV 60Hz %   100 100 100
U alpha soll V   2.73 2.73 2.73
Temperature output degC   T+-5
Measure T = actual output temperature


0000001301
Max. applied voltage V   8 8 8
Test voltage V   13 12 14


0000001401
K dimension mm   3.3 3.2 3.4
KF dimension mm   5.8 5.7 5.9
Pre-stroke mm   0.1 0.08 0.12

Test data Ex:



Injection timing adjustment Comp. resistor/voltage

Test data 104700-9153 Compensation resistance/compensation voltage comparison A = Compensation resistor number B= Compensation resistance C = Compensation voltage delta U alpha soll
----------

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0000001601 HARNESS & CONNECTOR

Test data 104700-9153 T.C.V. connector assembly specification (1)Ensure the GE cable is not twisted at section A. (2)Refer to diagram for direction of connector B. (3)Route the TCV harnes C in the direction indicated by the arrows in the figure and install the connector.
----------

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0000001701 HARNESS & CONNECTOR

Test data 104700-9153 Harness position specification (1)Ensure each dimension is as shown in the diagram and fix the harness using the binders. (2)Cut the binder leaving no more than L1 excess. (3)After completing all of the procedures, ensure no lead wires are exposed after routing the harness. A = GE, FCV, TCV, Q adjustment B=NP C=TPS E = binder
----------

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a=(75deg) L1=Max.2mm L2=75+-10mm L3=100+-10mm L4=100+-10mm



0000001801 HARNESS & CONNECTOR

Test data 104700-9153 Corrugated tube assembly specification (1)Align the end of the corrugated tube with clip A and fix it using black vinyl tape (L1, L2). (2)Confirm that the dimension to the end of the corrugated tube C is L3, and fix it using black vinyl tape (L4, L5). (3)Refer to the illustration for the position of the corrugated tube slit. A = binder B = outside edge of binder C = end of corrugated tube D = position of corrugated tube's slit
----------

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L1=Max.25mm L2=Max.10mm L3=265+-10mm L4=(20mm) L5=(30mm) a=45deg



0000001901 HARNESS & CONNECTOR

Test data 104700-9153 Harness fixing specification (1)Make the clearance between the clip J and the clip (B with metal end face) L1. (2)Fix clip B using socket head bolt D. At this time, adjust to within the tolerance L1 so that the TPS and NP harnesses in section A do not have excessive slack. (3)Clip the GE cable and the FCV harness using clip E, and the TPS-NP harness using clip G. (4)Attach the binder G after ensuring that the TPS cover H is not loose. B = clip D = socket head bolt E = binder G=Binder H = TPS cover J = binder
----------

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L1=240+-10mm L2=27~37mm T1=9.8~13.7N-m(1.0~1.4kgf-m)



0000002001 HARNESS & CONNECTOR

Test data 104700-9153 Vinyl tape assembly specification Wrap with vinyl tape at position A in the figure.
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L1=170+-10mm L2=25+-10mm L3=(20mm) L4=(20mm) L5=(10mm)



0000002101 HARNESS & CONNECTOR

Test data 104700-9153 Marking application specification (1)Ensure the corrugated tube is not twisted and then mark the position A shown in the figure. (2)3) Mark at the two locations indicated in the figure ( viewed from the side of the pump and the top of the pump). The markings must be the dimensions shown and approx. 5 mm wide. (3)2) Use indelible paint for steel. A = white marking B = End of tape binding
----------

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L1=20+-5mm





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Group cross 104700-9153 ZEXEL

104700-9150 
104700-9152 
9 460 614 225    INJECTION-PUMP ASSEMBLY
104700-9151 
104700-9150 
9 460 614 817    INJECTION-PUMP ASSEMBLY
104700-9152 
104700-9153 
9 460 614 830    INJECTION-PUMP ASSEMBLY
104700-9153  9 460 614 964    INJECTION-PUMP ASSEMBLY
4D56TCI

Hyundai 

104700-9153 
104700-9154 
9 460 614 964  3310542720  INJECTION-PUMP ASSEMBLY
4D56TCI
104700-9154 
104700-9155 
9 460 615 084  3310542720  INJECTION-PUMP ASSEMBLY
4D56TCI
104700-9155 
104700-9156 
F 01G 09W 0E1  3310542720  INJECTION-PUMP ASSEMBLY
4D56TCI
104700-9156    3310542720  INJECTION-PUMP ASSEMBLY
4D56TC
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