101491-9976 ZEXEL F 019 Z10 480 BOSCH INJECTION-PUMP ASSEMBLY f019z10480 1014919976 167000t072

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 019 Z10 480 f019z10480

ZEXEL 101491-9976 1014919976

NISSAN-DIESEL 167000T072 167000t072

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Buy INJECTION-PUMP ASSEMBLY 101491-9976 zexel genuine, new aftermarket engine parts with delivery

Service parts 101491-9976 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-9930

3. GOVERNOR 105921-6281

4. SUPPLY PUMP 105220-6020

5. AUTOM. ADVANCE MECHANIS 105671-0330

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5501

11. Nozzle and Holder 166000T003

12. Open Pre:MPa(Kqf/cm2) 18.6(190)

13. NOZZLE-HOLDER 105048-3760

14. NOZZLE

105017-1320

15. NOZZLE SET

Include in #1:

101491-9976 as INJECTION-PUMP ASSEMBLY

106672-9124 as _

Cross reference number

BOSCH F 019 Z10 480 f019z10480

ZEXEL 101491-9976 1014919976

NISSAN-DIESEL 167000T072 167000t072

Zexel num

Bosch num

Firm num

Name

101491-9976
101491-9977

F 019 Z10 480

167000T072 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
FD42 * 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 131424-1520

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 1-3-4-2

Pre-stroke mm 3.2 3.15 3.25

Rack position
Point A R=A

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point -

Rack position 12.5

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 71 69.4 72.6

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 9.6 7.8 11.4

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(12.5)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 71 70 72

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.2

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 79 75 83

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 100 84 116

Fixing the lever *

Timer adjustment

Pump speed r/min 1010--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 960

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min (1000)

Advance angle deg. 0.8 0.5 1.1

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 1330+30- 20

Advance angle deg. 0.8 0.5 1.1

Timer adjustment_05

Pump speed r/min 1500

Advance angle deg. 3.45 3.45 3.45

Timer adjustment_06

Pump speed r/min 1600

Advance angle deg. 5 4.5 5.5

Remarks
Finish

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=G84
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=32mm
----------
a=70deg+-5deg b=37deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=12mm
----------
a=29deg+-5deg b=10deg+-5deg

0000001501 LEVER

(A) Speed lever (lower) (B) Stopper bolt (C) Special lever (upper) a:Point A (inside lever) 1. Special lever adjustment (1)With the speed lever at the idle position, set the accelerator lever stopper bolt so that the accelerator lever contacts the speed lever at point a. (2)Back off the stopper bolt L and set.
----------
L=1+0.5mm
----------

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole (position of gear mark 'S') at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=12deg
----------
a=(60deg)

Information:

2. Locate wire 405-GY on the main cab harness near the connector exiting the cab wall on the right hand side, as shown by arrow.Cut this wire close to the connector. Splice it and the wire just assembled using an 8S4626 Splice. Be sure to splice to the portion of the wire that goes into the cab harness.3. Connect the 7N9738 Housing to the two pin connector on the 8X9862 Harness Assembly (housing containing 405-GY). Clip with a 3T3048 Clip Assembly.Installation of Ether (Chassis) Wiring Harness
The ether chassis harness for MPPS is different than the one called out in the AEIS Special Instruction.* Substitute 8X8468 Harness Assembly for 8X7653 Harness Assembly on the 785 Trucks.* Substitute 8X8467 Harness Assembly for 8X7652 Harness Assembly on the 789 Trucks.Follow the installation procedure outlined in the AEIS Special Instruction for the Ether Chassis Harness Assembly. Be sure to use the 8X8466 Wire Assembly for the 785 Trucks or the 8X8429 Wire Assembly for the 789 Trucks. This is the new harness code plug required with MPPS.Installation of 8X8469 Ether (Engine) Wiring Harness
The 8X7106 Engine Harness on the AEIS is replaced with 8X8469 Harness Assembly.Follow the installation procedure outlined in the AEIS Special Instruction for the 8X7106 Harness Assembly. In addition, the following steps need to be performed. 1. Route the end of the harness with the 8T8732 Receptacle to the 3E3530 Electronic Control Group (oil pressure sensor) installed at the right rear of the engine as shown.2. Connect the three pin receptacle to the connector on the 3E3530 Electronic Control Group (2) and clip into the 9X3495 Clip Assembly (7) installed earlier. Use 3S2093 Straps (8) to loosely secure the harness to the top rear of the engine as shown.3. Remove the 8W3048 Harness Assembly that is connected to the remaining 6T7663 Oil Pressure Switch (9) and was connected to the 6T7663 Oil Pressure Switch (9) that was removed.4. Connect an 8X8337 Harness Assembly (10) to the one remaining oil pressure switch and reconnect to the engine harness. Clip with the existing clip. DO NOT tighten the straps or clips until all new wiring harnesses have been installed so any repositioning or adjustments can be made as necessary.Checking the Automatic Ether Injection System
* The system check-out will be same as for the AEIS with the following change: "A5" harness code on the 785 (indicates 3512 application) or "A6" harness code on the 789 (indicates 3516 application) for two seconds.Retrofit to an Existing AEIS System
Necessary Parts
Installation of 3E3778 Ether Control Group
The 3E3778 Control Group is required for the MPPS System.Check the electronic control box installed with the AEIS to see if it is a 3E3778 or a 9X5303 Control Group. If a 9X5303 control Group is installed, replace it with 3E3778 Control Group and 3E3779 Film.Follow the "Installation of 9X5303 Ether Control Group" instructions outlined in the AEIS installation Special Instruction, SEHS9293. Be sure to install the 8X8398 Wire Assembly between the control and mounting plate. If an MPPS identification film is