101603-9030 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016039030

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-9030 1016039030

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Cross reference number

ZEXEL 101603-9030 1016039030

Zexel num

Bosch num

Firm num

Name

101603-9030
101606-9500

NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
FE6B *

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 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 1-4-2-6- 3-5

Pre-stroke mm 3.4 3.35 3.45

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point -

Rack position 11.8

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 66.3 64.7 67.9

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. 9.5 7.7 11.3

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(11.8)

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 66.3 65.3 67.3

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.2

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 73 69.8 76.2

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1(11.8)

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 83.9 79.9 87.9

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 84 84 94

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 850--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 800

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 4 3.5 4.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=B55
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=26.5deg+-5deg b=40deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=20deg+-5deg b=40deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(60deg)

Information:

1. Disconnect the fuel priming pump fuel inlet line (1).2. Disconnect the fuel supply line.3. Remove the two mounting bolts (2) and remove the tachometer drive (4).4. Remove the two mounting bolts (3) and remove the fuel transfer pump.Install Fuel Transfer Pump
1. Position the fuel transfer pump on the engine and install the mounting bolts.2. Install the tachometer drive.3. Connect the fuel supply line.4. Connect the fuel priming pump fuel inlet line.5. Prime the fuel system and bleed off the air, with the fuel priming pump.Disassemble Fuel Transfer Pump
preparatory step: a) remove fuel transfer pump1. Remove the gear retaining nut (2), gear (3), and woodruff key.2. Remove the cage assembly (1).3. Remove the O-ring seals from the cage assembly. 4. Using tool (A), remove the bearing and lip-type seals from cage. 5. Remove the cover assembly (5).
Be careful not to damage mating surfaces of cover assembly and pump body.
6. Remove the seal from the cover assembly.7. Remove the gear (4), and gear and shaft assembly (6) from pump body. 8. Using tool (A), remove the bearing from pump body.Assemble Fuel Transfer Pump
1. Clean all parts thoroughly before assembling pump. 2. Using tool (A), install the bearing in pump body.3. Position the gear, and gear and shaft assembly in body. 4. Using tool (B), install the seal in the cover assembly.5. Apply a thin film of 8S6747 Liquid Gasket Material to face of body assembly.
Do not allow liquid gasket material to enter pump.
6. Install the cover assembly on pump body. After tightening cover assembly retaining bolts, the gear and shaft assembly must rotate freely. 7. Using tool (B), install the seals in the cage. Install the inner seal with lip of seal toward pump drive gear. Install the outer seal with lip toward pump body. 8. Using tool (A), install the bearing in the cage assembly.9. Install the O-ring seals on cage assembly.10. Lubricate the O-ring seals and lip-type seals with clean SAE 30 engine oil.11. Position the cage assembly on the gear and shaft assembly.12. Install the woodruff key, gear, and retaining nut. Tighten the retaining nut to 22 5 lb. ft. (3,0 0,7 mkg).concluding step: a) install fuel transfer pump