Information injection-pump assembly
BOSCH
9 400 619 601
9400619601
ZEXEL
101603-9370
1016039370
NISSAN-DIESEL
16713Z5770
16713z5770
Rating:
Service parts 101603-9370 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600Z5519
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Include in #1:
101603-9370
as INJECTION-PUMP ASSEMBLY
Include in #2:
104741-5860
as _
Cross reference number
BOSCH
9 400 619 601
9400619601
ZEXEL
101603-9370
1016039370
NISSAN-DIESEL
16713Z5770
16713z5770
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
850--
Advance angle
deg.
0
0
0
Remarks
Start
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
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 oil pan1. Turn the crankshaft until two pistons are at bottom center. Remove connecting rod caps (1) from the two connecting rods. Remove the lower half of the bearings from the caps.2. Push the connecting rods away from the crankshaft and remove the upper half of the bearings.
Be careful not to damage the crankshaft journals. Do not turn the crankshaft while any of the connecting rod caps are removed.
Install the bearings dry when the clearance checks are made. Put clean engine oil on the bearings for final assembly.3. Clean the surfaces where the bearings fit. Install the upper half of the bearing in the connecting rod. Pull the connecting rod slowly on to the crankshaft.4. Install lower half of the bearing in the cap.
When the connecting rod caps are installed, make sure that the numbers on the side of the caps are next to and respective with the number on the side of the connecting rods.
Typical Example5. Check the bearing clearance with Plastigage (A). Put Plastigage (A) on the bearing.6. Put 2P2506 Thread Lubricant on the threads of the rod bolts and seat surfaces of the nuts.
Do not use an impact wrench to tighten the nuts the additional 60 5°.
Do not turn the crankshaft when Plastigage (A) is in position. 7. Put caps (1) in position on the connecting rods and install the nuts. Tighten the nuts to a torque of 40 4 N m (30 3 lb.ft.). Put a mark on each nut and the end of each bolt. Tighten the nuts 60 5° more.8. Remove the cap. Measure the thickness of Plastigage (A). The rod bearing clearance must be 0.053 to 0.140 mm (.0021 to .0055 in.). The maximum permissible clearance is 0.15 mm (.006 in.).9. Put the caps in position on the connecting rods and install the nuts. Tighten the nuts to a torque of 40 4 N m (30 3 lb.ft.). Put a mark on each nut and the end of each bolt. Tighten the nuts 60 5° more.10. Do Steps 1 through 9 again for other bearings. end by:a) install oil pan
Be careful not to damage the crankshaft journals. Do not turn the crankshaft while any of the connecting rod caps are removed.
Install the bearings dry when the clearance checks are made. Put clean engine oil on the bearings for final assembly.3. Clean the surfaces where the bearings fit. Install the upper half of the bearing in the connecting rod. Pull the connecting rod slowly on to the crankshaft.4. Install lower half of the bearing in the cap.
When the connecting rod caps are installed, make sure that the numbers on the side of the caps are next to and respective with the number on the side of the connecting rods.
Typical Example5. Check the bearing clearance with Plastigage (A). Put Plastigage (A) on the bearing.6. Put 2P2506 Thread Lubricant on the threads of the rod bolts and seat surfaces of the nuts.
Do not use an impact wrench to tighten the nuts the additional 60 5°.
Do not turn the crankshaft when Plastigage (A) is in position. 7. Put caps (1) in position on the connecting rods and install the nuts. Tighten the nuts to a torque of 40 4 N m (30 3 lb.ft.). Put a mark on each nut and the end of each bolt. Tighten the nuts 60 5° more.8. Remove the cap. Measure the thickness of Plastigage (A). The rod bearing clearance must be 0.053 to 0.140 mm (.0021 to .0055 in.). The maximum permissible clearance is 0.15 mm (.006 in.).9. Put the caps in position on the connecting rods and install the nuts. Tighten the nuts to a torque of 40 4 N m (30 3 lb.ft.). Put a mark on each nut and the end of each bolt. Tighten the nuts 60 5° more.10. Do Steps 1 through 9 again for other bearings. end by:a) install oil pan