101603-9040 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016039040 1671395100

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-9040 1016039040

NISSAN-DIESEL 1671395100 1671395100

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Service parts 101603-9040 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-3380

3. GOVERNOR 105480-0680

4. SUPPLY PUMP 105220-7050

5. AUTOM. ADVANCE MECHANIS 105614-3350

6. COUPLING PLATE 105661-0601

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-5341

11. Nozzle and Holder 1660095013

12. Open Pre:MPa(Kqf/cm2) 19.6(200)

13. NOZZLE-HOLDER 105031-4620

14. NOZZLE

105015-6981

15. NOZZLE SET

Include in #1:

101603-9040 as INJECTION-PUMP ASSEMBLY

Include in #2:

104749-5260 as _

Cross reference number

ZEXEL 101603-9040 1016039040

NISSAN-DIESEL 1671395100 1671395100

Zexel num

Bosch num

Firm num

Name

101603-9040

1671395100 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
NE6 * K 14BE PE6A PE

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 2.75 2.7 2.8

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 A

Rack position 9.7

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 79.1 78.1 80.1

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 7.5+-0.5

Pump speed r/min 285 285 285

Average injection quantity mm3/st. 13 11.2 14.8

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Timer adjustment

Pump speed r/min 550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 800

Advance angle deg. 1.5 1 2

Timer adjustment_04

Pump speed r/min 1200

Advance angle deg. 4 3.5 4.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Excess fuel setting for starting: SXL (4)Damper spring setting: DL
----------
RT=1 TH=2.7mm SXL=11.8+0.2mm DL=5.7-0.2mm
----------

Speed control lever angle

F:Full speed
----------

----------
a=(9.5deg)+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=18deg+-5deg b=21deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=20mm
----------
a=71deg+-5deg b=40deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of coupling's key groove at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(40deg)

Information:

preparatory step: a) remove oil pan1. Remove the suction screen mounting bolt.2. Remove the oil pump mounting bolts (1).3. Remove the oil pump-weight 40 lbs. (18,1 kg).Install Oil Pump
Prime the oil pump with SAE 30 engine oil before installation.
1. Position the oil pump on the engine, and install the pump mounting bolts and screen mounting bolt.concluding step: a) install oil panDisassemble Oil Pump
preparatory step: a) remove oil pump 1. Remove the oil pump idler gear (1). Using tool setup (A), remove the bearing from the gear.2. Remove the suction bell assembly (2) and relief valve oil tube (3). 3. Remove the relief valve (4) and spring (5).4. Using tool setup (B), pull the oil pump drive gear from the shaft. Remove the woodruff key. 5. Remove the oil pump housing cover (6).6. Remove the pump gears. 7. Using tool setup (C), remove the bearings from the pump housing and gear.8. Remove the bearing from the pump housing cover.Assemble Oil Pump
1. Using tool setup (A), install the bearing in the oil pump idler gear. Recess the bearing edge flush with the inner edge of the chamfer. 2. Using tool setup (B), install the bearings in the pump housing, pump gear and pump housing cover. Recess the bearing edge flush with the inner edge of the chamfer. 3. Lubricate the bearings, gears (1) and shaft with clean SAE 30 engine oil. Install the gears into the pump housing.4. Install the oil pump housing cover (2).5. Heat the oil pump drive gear to 350°F (177°C). Install the woodruff key and gear on the pump shaft.6. Install the relief valve and spring.7. Install the suction bell assembly, relief valve oil tube and install idler gear.concluding step: a) install oil pump