101603-9401 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016039401 16713z5773

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-9401 1016039401

NISSAN-DIESEL 16713Z5773 16713z5773

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Cross reference number

ZEXEL 101603-9401 1016039401

NISSAN-DIESEL 16713Z5773 16713z5773

Zexel num

Bosch num

Firm num

Name

101603-9401

16713Z5773 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
FE6B * K

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 131424-1520

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)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=C43
----------

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:

start by:a) remove flywheel housingb) remove valve liftersc) remove pistonsd) remove timing gear cover and oil pump1. Fasten a hoist and put the engine in position on tool (A).2. Turn the crankshaft until the timing mark on the crankshaft gear is in alignment with the timing mark on the camshaft gear. For more detail about removal of main bearings see REMOVE AND INSTALL CRANKSHAFT MAIN BEARINGS. 3. Remove bolts (1) and main bearing caps (2). Remove the lower halves of the main bearings from the caps.4. Install two of the bolts that hold the flywheel in place in the end of crankshaft. 5. Fasten a hoist and remove crankshaft (3) from the engine. The weight of the crankshaft is 54 kg (120 lb.).
Be careful not to cause damage to the crankshaft journals when the crankshaft is removed.
6. Remove the upper halves of the main bearings from the cylinder block.7. Install tooling (B) and remove the gear from the crankshaft. Install Crankshaft And Gear
1. Install the key for the crankshaft gear so it is even with the end of the crankshaft.2. Heat the crankshaft gear to a maximum temperature of 260°C (500°F). Install the gear on the crankshaft with the timing mark on the gear toward the pulley end of the crankshaft.3. Install the thrust bearing for the No. 4 main. Install the bearings dry when the clearance checks are made. Put clean engine oil on the bearings for final assembly.4. Install the upper main bearings (the bearings with oil hole) into the engine block.5. Install two of the bolts that hold the flywheel in place in the end of the crankshaft. Fasten a hoist and put the crankshaft in position in the block. Make sure the timing mark on the crankshaft gear is in alignment with the timing mark on the camshaft gear. For more detail about installation of main bearings see REMOVE AND INSTALL CRANKSHAFT MAIN BEARINGS.
When the bearing caps are installed, make sure the number on the side of the cap is next to and respective with the number on the engine block.
When the bearing clearance is checked and the engine is in a vertical position, the crankshaft will have to be lifted up with a force equal to the weight of the crankshaft and held against the upper halves of the main bearings to get a correct measurement with Plastigage. The Plastigage will not hold the weight of the crankshaft and give a correct indication. If the engine is in a horizontal position, such as on an engine stand, it is not necessary to hold the crankshaft up. Do not turn crankshaft when Plastigage is in position to check clearance. 6. Check the bearing clearance with Plastigage. Put the lower main bearings into the caps. Put the caps in position and install the bolts. Tighten the bolts in number sequence as follows: a) Tighten bolts 1 through 10 to a torque of 40 4 N m (30 3 lb.ft.).
Do not use an impact