Information injection-pump assembly
ZEXEL
101603-9440
1016039440
NISSAN-DIESEL
16713Z5811
16713z5811
Rating:
Service parts 101603-9440 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
Include in #1:
101603-9440
as INJECTION-PUMP ASSEMBLY
Include in #2:
104741-5620
as _
Cross reference number
ZEXEL
101603-9440
1016039440
NISSAN-DIESEL
16713Z5811
16713z5811
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
134424-1520
Overflow valve opening pressure
kPa
162
147
177
Overflow valve opening pressure
kgf/cm2
1.65
1.5
1.8
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
11.6
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
65.2
63.6
66.8
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.
9.2
7.4
11
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(11.6)
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
65.2
64.2
66.2
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.65
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
85.9
81.9
89.9
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1(11.6)
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
56.5
53.3
59.7
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
82
82
92
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.
5
4.5
5.5
Remarks
Finish
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=E21
----------
----------
T1=E21
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=26.5deg+-5deg b=40.5deg+-3deg
----------
----------
a=26.5deg+-5deg b=40.5deg+-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:
(1) Large bolts (3/4 inch). Put 6V4876 Molycoat on all bolt threads and under all bolt heads. Tighten the bolts in the following step sequence:Step 1. Tighten bolts from 1 through 20 in number sequence to ... 270 25 N m (200 20 lb ft)Step 2. Tighten bolts from 1 through 20 in number sequence to ... 450 20 N m (330 15 lb ft)Step 3. Tighten bolts from 1 through 20 in number sequence again to ... 450 20 N m (330 15 lb ft)Step 4. Install the rocker arm shafts for the engine valves.Step 5. Tighten bolts from 21 through 26 in number sequence to ... 270 25 N m (200 20 lb ft)Step 6. Tighten bolts from 21 through 26 in number sequence to ... 450 20 N m (330 15 lb ft)Step 7. Tighten bolts from 21 through 26 in number sequence again to ... 450 20 N m (330 15 lb ft)Step 8. Tighten the twelve small bolts (2) to ... 45 7 N m (33 5 lb ft)(2) Small bolts (3/8 inch). See Step 8 above.(3) Torque for twelve studs in cylinder head ... 30 5 N m (22 4 lb ft) (4) Thickness of cylinder head (new) ... 112.78 0.25 mm (4.440 .010 in) Minimum permissible thickness of cylinder head ... 111.51 mm (4.390 in)(5) Torque for six studs that hold fuel line adapter locks ... 30 5 N m (22 4 lb ft) Flatness of the cylinder head should be within 0.13 mm (.005 in) total, and a maximum of 0.03 mm (.001 in) for any 76.2 mm (3.00 in) span.
When the cylinder head is installed on an engine with a water cooled exhaust manifold, plug (A) MUST be removed to prevent damage to the water cooled exhaust manifold. If the engine has a dry exhaust manifold, plug (A) MUST NOT be removed.
When the cylinder head is installed on an engine with a water cooled exhaust manifold, plug (A) MUST be removed to prevent damage to the water cooled exhaust manifold. If the engine has a dry exhaust manifold, plug (A) MUST NOT be removed.