Information injection-pump assembly
ZEXEL
101603-9381
1016039381
Rating:
Service parts 101603-9381 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:
101603-9381
as INJECTION-PUMP ASSEMBLY
Include in #2:
104741-5862
as _
Cross reference number
ZEXEL
101603-9381
1016039381
Zexel num
Bosch num
Firm num
Name
101603-9381
INJECTION-PUMP ASSEMBLY
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
132424-0620
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 set position 'H'
----------
----------
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 panb) remove crankshaft pulley1. Remove nuts (2) and tachometer drive cover (1). 2. Remove bolts (3) and front support (4). 3. Loosen clamp (5) and disconnect hose (6) from the timing gear cover. 4. Remove clips (8) and then disconnect three lines (7). 5. Remove clamp (9) from the water sleeve.6. Install tool (A) on the water sleeve and then push water sleeve (10) into the front cover. 7. Remove two bolts (11), connector (12) and the gasket behind it. 8. Remove bolts (13), elbow (14) and the gasket behind it. 9. Remove bolt (15) and then disconnect clamp (16) that holds the oil pump sump tube. 10. Install tooling (B) in the front cover and then fasten a hoist. Remove all the bolts that hold timing gear cover to the cylinder block. Remove the cover (17) and oil pump. The weight of the timing gear cover and oil pump is 62 kg (136 lb.).
Be extra careful not to cause damage to the crankshaft front seal during removal and installation of the timing gear cover.
Install Timing Gear Cover And Oil Pump
1. Clean the contact surfaces of the cylinder block and timing gear cover. Install the timing gear cover gasket on the cylinder block. Make sure the water sleeves are installed in the timing gear cover. Put oil on the seals on the water sleeves. 2. Install tooling (A) on timing gear cover (1).3. Put the cover in position and make an alignment of the dowels and their respective holes. Install the bolts that hold cover (1) to the cylinder block. 4. Connect clamp (3) that holds the oil pump sump tube. Install bolt (2). 5. Install gasket and elbow (4) on the timing gear cover with the bolts (5) that hold it.6. Install gasket and connector (7) in the cover and install the bolts (6) that hold it. 7. Install tool (B) on water sleeve (8), then push water sleeve into the cylinder block. 8. Install clamps (9) on the water sleeve. 9. Connect three lines (10) and install the clips (11) that hold them. 10. Install hose (13) on timing gear cover and install clamp (12). 11. Put engine support (16) in position and install the bolts (17) that hold it. 12. Put tachometer cover (15) in position and install the nuts (14) that hold it. end by:a) install crankshaft pulleyb) install oil pan
Be extra careful not to cause damage to the crankshaft front seal during removal and installation of the timing gear cover.
Install Timing Gear Cover And Oil Pump
1. Clean the contact surfaces of the cylinder block and timing gear cover. Install the timing gear cover gasket on the cylinder block. Make sure the water sleeves are installed in the timing gear cover. Put oil on the seals on the water sleeves. 2. Install tooling (A) on timing gear cover (1).3. Put the cover in position and make an alignment of the dowels and their respective holes. Install the bolts that hold cover (1) to the cylinder block. 4. Connect clamp (3) that holds the oil pump sump tube. Install bolt (2). 5. Install gasket and elbow (4) on the timing gear cover with the bolts (5) that hold it.6. Install gasket and connector (7) in the cover and install the bolts (6) that hold it. 7. Install tool (B) on water sleeve (8), then push water sleeve into the cylinder block. 8. Install clamps (9) on the water sleeve. 9. Connect three lines (10) and install the clips (11) that hold them. 10. Install hose (13) on timing gear cover and install clamp (12). 11. Put engine support (16) in position and install the bolts (17) that hold it. 12. Put tachometer cover (15) in position and install the nuts (14) that hold it. end by:a) install crankshaft pulleyb) install oil pan
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Nissan-Diesel
Nissan-Diesel
Nissan-Diesel
Nissan-Diesel
101603-9381
INJECTION-PUMP ASSEMBLY