Information injection-pump assembly
ZEXEL
101401-7183
1014017183
NISSAN
1670089TD0
1670089td0
Rating:
Service parts 101401-7183 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97119-812-0
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
ZEXEL
101401-7183
1014017183
NISSAN
1670089TD0
1670089td0
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
131424-4920
Overflow valve opening pressure
kPa
127
107
147
Overflow valve opening pressure
kgf/cm2
1.3
1.1
1.5
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-3-4-2
Pre-stroke
mm
4.1
4.05
4.15
Rack position
Point E R=E
Point E R=E
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
-
Rack position
11.9
Pump speed
r/min
1310
1310
1310
Average injection quantity
mm3/st.
64.5
62.9
66.1
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
9.8+-0.5
Pump speed
r/min
285
285
285
Average injection quantity
mm3/st.
15.5
14.2
16.8
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.9)
Pump speed
r/min
1310
1310
1310
Average injection quantity
mm3/st.
64.5
63.5
65.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1
Pump speed
r/min
1600
1600
1600
Average injection quantity
mm3/st.
67.5
63.5
71.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.5
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
44.7
40.7
48.7
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
E
Rack position
R1-0.05
Pump speed
r/min
960
960
960
Average injection quantity
mm3/st.
58.5
54.5
62.5
Fixing the lever
*
Timer adjustment
Pump speed
r/min
-
Advance angle
deg.
0
0
0
Remarks
Measure speed (beginning of operation).
Measure speed (beginning of operation).
Timer adjustment_02
Pump speed
r/min
-
Advance angle
deg.
5
4.5
5.5
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
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.
----------
T1=L31
----------
----------
T1=L31
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=41deg+-5deg b=34deg+-3deg
----------
----------
a=41deg+-5deg b=34deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
----------
aa=64mm
----------
a=20deg+-5deg b=29deg+-5deg
----------
aa=64mm
----------
a=20deg+-5deg b=29deg+-5deg
0000001501 RACK SENSOR
Rack sensor adjustment
1. Flange type rack sensor (rack sensor adjustment -5*20)
(1)These types of rack sensors do not need adjustment. Confirm the performance with the following procedures.
(2)Mount the rack sensor main body to the pump main body.
(3)Fix the pump lever at full.
(4)At supply voltage V1, pump speed N1 and rack position Ra, confirm that the amp's output voltage is Vist.
(5)Move the pump lever two or three times.
(6)Set again to full.
(7)Confirm that the amplifier output voltage is Vist.
(8)Fix the caution plate to the upper part of the rack sensor.
(For those without the caution plate instructions, make sure the nameplate of the rack sensor carries the "Don't hold here" caution.)
(9)Apply red paint to the rack sensor mounting bolts (2 places).
----------
V1=5+-0.01V N1=960r/min Ra=R1(11.9)-0.05mm Vist=2.61+-0.28V
----------
----------
V1=5+-0.01V N1=960r/min Ra=R1(11.9)-0.05mm Vist=2.61+-0.28V
----------
0000001601 FICD
(A) applied negative pressure
(B) Screw
(c) Nut
1. Set the actuator as described below.
(1)Confirm that there is clearance between the actuator lever and the speed lever.
(2)Loosen the nut (C).
(3)Push in the screw (B).
(4)Apply P1 from the actuator (A) part.
(5)Pull out the screw (B) slowly.
(6)Tighten and fix the nut (C) when pump speed is Na and the rack position is Ra.
(7)Torque the nut (C) to T1.
(8)Apply P2 several times.
(9)Confirm that the actuator functions normally.
(10)Confirm that there is a clearance between the actuator lever and the speed lever at that time.
----------
P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) Na=440r/min Ra=9.2+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(5)mm
----------
P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) Na=440r/min Ra=9.2+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(5)mm
Timing setting
(1)Pump vertical direction
(2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection
(3)Stamping position on the A/T outer rim
(4)Pump bracket check hole position.
(5)At the No 1 cylinder's beginning of injection, align with the projection seen through the bracket's check hole and mark the A/T's bevel C1.
(6)B.T.D.C.: aa
----------
aa=7deg
----------
a=(60deg) b=(85deg)
----------
aa=7deg
----------
a=(60deg) b=(85deg)
Information:
1. Remove the fuel injection lines. It is not necessary to remove the fuel transfer pump, the fuel injection pump housing and governor to remove the fuel injection pumps. 2. Remove cover (1). 3. Move the rack until tool (A) can be installed to hold the rack in the center position. The rack must be in the center position to remove the fuel injection pumps.4. Use tool (B) to remove bushing (2). 5. Install tool (C) on the bonnet and remove the fuel injection pump. 6. Remove spacer (3) from the fuel injection pump housing. Spacers (3) are the same thickness for each fuel injection pump so they can be mixed. The fuel injection pump plungers and barrels are sets and can not be mixed.Install Fuel Injection Pumps
1. Install spacer (1) in the fuel injection pump housing. 2. Move the rack until tool (A) can be installed to hold the rack in the center position. The rack must be in the center position to install the fuel injection pumps.3. Turn the camshaft until the lobe of the camshaft is down for the pump to be installed. 4. Install tool (B) on the bonnet of the fuel injection pump. Put clean oil on O-ring seal (4) and install the O-ring seal and bushing (5) over tool (B) as shown. 5. Install the fuel injection pump in the pump housing with saw cut (slot) (3) in the gear in alignment with small pin (2) in the lifter assembly and groove (7) in the barrel in alignment with large pin (6) in the pump housing.6. Push down on tool (B) and tighten bushing (5) by hand until the bushing is even with the top of the housing. If installation of the bushing can not be made this far by hand, remove it. Remove the pump, put the parts in alignment again and install the bushing again.
If installation of pump is correct, the bushing can be tightened by hand until it is even with the face of the pump housing.
7. Remove tool (B) and install tool (C) in the bushing. Use tool (C) and a torque wrench to tighten the bushing to a torque of 165 14 N m (120 10 lb. ft.).8. Remove tools (C) and (A). Install the cover on the fuel injection pump housing.9. Install the fuel injection lines. Tighten the fuel injection line nuts to a torque of 41 7 N m (30 5 lb.ft.).Disassemble Fuel Injection Pumps
start by:a) remove fuel injection pumps
Be careful when the injection pumps are disassembled. Do not damage the surfaces of the plungers, barrels and bonnets. Any scratches will cause leakage inside the fuel injection pump. The plunger and barrel for each pump are made as a set. Do not put the plunger of one pump in the barrel of another pump. If one part has wear, install a complete new pump assembly. Be careful when the plunger is put into the bore of the barrel.
1. Pull plunger (1)
1. Install spacer (1) in the fuel injection pump housing. 2. Move the rack until tool (A) can be installed to hold the rack in the center position. The rack must be in the center position to install the fuel injection pumps.3. Turn the camshaft until the lobe of the camshaft is down for the pump to be installed. 4. Install tool (B) on the bonnet of the fuel injection pump. Put clean oil on O-ring seal (4) and install the O-ring seal and bushing (5) over tool (B) as shown. 5. Install the fuel injection pump in the pump housing with saw cut (slot) (3) in the gear in alignment with small pin (2) in the lifter assembly and groove (7) in the barrel in alignment with large pin (6) in the pump housing.6. Push down on tool (B) and tighten bushing (5) by hand until the bushing is even with the top of the housing. If installation of the bushing can not be made this far by hand, remove it. Remove the pump, put the parts in alignment again and install the bushing again.
If installation of pump is correct, the bushing can be tightened by hand until it is even with the face of the pump housing.
7. Remove tool (B) and install tool (C) in the bushing. Use tool (C) and a torque wrench to tighten the bushing to a torque of 165 14 N m (120 10 lb. ft.).8. Remove tools (C) and (A). Install the cover on the fuel injection pump housing.9. Install the fuel injection lines. Tighten the fuel injection line nuts to a torque of 41 7 N m (30 5 lb.ft.).Disassemble Fuel Injection Pumps
start by:a) remove fuel injection pumps
Be careful when the injection pumps are disassembled. Do not damage the surfaces of the plungers, barrels and bonnets. Any scratches will cause leakage inside the fuel injection pump. The plunger and barrel for each pump are made as a set. Do not put the plunger of one pump in the barrel of another pump. If one part has wear, install a complete new pump assembly. Be careful when the plunger is put into the bore of the barrel.
1. Pull plunger (1)