Information injection-pump assembly
ZEXEL
101603-9350
1016039350
NISSAN-DIESEL
16713Z5768
16713z5768
Rating:
Service parts 101603-9350 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-Z5519
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
ZEXEL
101603-9350
1016039350
NISSAN-DIESEL
16713Z5768
16713z5768
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 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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
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
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
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
1250--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1200
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1500
Advance angle
deg.
4
3.5
4.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
----------
T1=C43
----------
----------
T1=C43
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=26.5deg+-5deg b=40deg+-3deg
----------
----------
a=26.5deg+-5deg b=40deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=20deg+-5deg b=40deg+-5deg
----------
----------
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)
----------
----------
a=(60deg)
Information:
start by:a) remove exhaust manifoldb) remove air inlet manifoldc) remove valve coversd) remove fuel injection linese) remove fuel injection nozzles1. Remove the coolant from the cooling system. 2. Remove clamp (2) from water sleeves (1) in each cylinder head. Push the water sleeves into the timing gear cover with tool (A) and a screwdriver. 3. Remove bolt (3) from the bracket on the dipstick tube. 4. Remove bolts (4) and stud (5) from the heads.
Make sure the fuel injection nozzles are removed before the cylinder heads are removed. The fuel injection nozzles go through the cylinder heads and the nozzle tips can be broken off if the nozzles are not removed from the heads.
5. Install tooling (B) and fasten a hoist. Remove bolts (7), cylinder head (6) and the gasket. The weight of the cylinder head is 54 kg (120 lb.).Install Cylinder Heads
1. Clean the contact surfaces of the cylinder head and cylinder block. Make sure the surfaces are clean and dry. Install a new cylinder head gasket. Clean the bore in the cylinder head for the water sleeves. Put oil on the seals on the water sleeves.2. Install tooling (B) in the cylinder head. Fasten a hoist and put the cylinder head in position on the cylinder block.3. Put 6V4876 Molykote Lubricant on the bolt threads and install the bolts that hold the cylinder head in their correct location. Tighten the bolts in the cylinder head according to the HEAD BOLT TORQUE CHART.
The higher cylinder head bolt torque may be used on earlier engines ONLY if the bolts are replaced with the later higher strength bolts (seven dash marks on the bolt head). If the earlier bolts are tightened to the later torque specification, they may yield (stretch) and lose their clamping force.
4. Install water sleeve into cylinder head with tool (A). Install the clamp on the water sleeves.5. Fill the cooling system with coolant to the correct level. end by:a) install fuel injection nozzlesb) install rocker shafts and push rodsc) install valve coversd) install air inlet manifolde) install exhaust manifold
Illustration 1. Bolt head identification.Disassemble Cylinder Heads
start by: a) remove cylinder heads1. Fasten a hoist and put the cylinder head in position on tool (A). Use adapter plates (1) from tooling (A) to hold the head in place. 2. Put the valve springs under compression with tool (C). 3. Remove the locks from the valves. Earlier engines have an inner valve spring. Later engines have only one valve spring and a spacer instead of inner spring.4. Remove tool (C), retainer, spring, washer and valve from the cylinder head. Put identification on the valve as to its location in the cylinder head. 5. Check the valve spring force with tool (B). For the correct spring force, see the subject VALVES in SPECIFICATIONS.6. Do Steps 2 through 5 for the remainder of the valves.7. Remove the valve seat inserts with tooling (D). The valve guides are part of the cylinder head. Measure the bore in each valve guide 19.0
Make sure the fuel injection nozzles are removed before the cylinder heads are removed. The fuel injection nozzles go through the cylinder heads and the nozzle tips can be broken off if the nozzles are not removed from the heads.
5. Install tooling (B) and fasten a hoist. Remove bolts (7), cylinder head (6) and the gasket. The weight of the cylinder head is 54 kg (120 lb.).Install Cylinder Heads
1. Clean the contact surfaces of the cylinder head and cylinder block. Make sure the surfaces are clean and dry. Install a new cylinder head gasket. Clean the bore in the cylinder head for the water sleeves. Put oil on the seals on the water sleeves.2. Install tooling (B) in the cylinder head. Fasten a hoist and put the cylinder head in position on the cylinder block.3. Put 6V4876 Molykote Lubricant on the bolt threads and install the bolts that hold the cylinder head in their correct location. Tighten the bolts in the cylinder head according to the HEAD BOLT TORQUE CHART.
The higher cylinder head bolt torque may be used on earlier engines ONLY if the bolts are replaced with the later higher strength bolts (seven dash marks on the bolt head). If the earlier bolts are tightened to the later torque specification, they may yield (stretch) and lose their clamping force.
4. Install water sleeve into cylinder head with tool (A). Install the clamp on the water sleeves.5. Fill the cooling system with coolant to the correct level. end by:a) install fuel injection nozzlesb) install rocker shafts and push rodsc) install valve coversd) install air inlet manifolde) install exhaust manifold
Illustration 1. Bolt head identification.Disassemble Cylinder Heads
start by: a) remove cylinder heads1. Fasten a hoist and put the cylinder head in position on tool (A). Use adapter plates (1) from tooling (A) to hold the head in place. 2. Put the valve springs under compression with tool (C). 3. Remove the locks from the valves. Earlier engines have an inner valve spring. Later engines have only one valve spring and a spacer instead of inner spring.4. Remove tool (C), retainer, spring, washer and valve from the cylinder head. Put identification on the valve as to its location in the cylinder head. 5. Check the valve spring force with tool (B). For the correct spring force, see the subject VALVES in SPECIFICATIONS.6. Do Steps 2 through 5 for the remainder of the valves.7. Remove the valve seat inserts with tooling (D). The valve guides are part of the cylinder head. Measure the bore in each valve guide 19.0