Information injection-pump assembly
ZEXEL
101606-9900
1016069900
NISSAN-DIESEL
1671395274
1671395274
Rating:
Cross reference number
ZEXEL
101606-9900
1016069900
NISSAN-DIESEL
1671395274
1671395274
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
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
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
3.9
3.85
3.95
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
12.8
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
91
89.4
92.6
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
-
Rack position
9.6+-0.5
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
9
7.2
10.8
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.8)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
91
90
92
Basic
*
Fixing the lever
*
Boost pressure
kPa
33.3
33.3
Boost pressure
mmHg
250
250
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+1.15
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
120.5
117.3
123.7
Fixing the lever
*
Boost pressure
kPa
33.3
33.3
Boost pressure
mmHg
250
250
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-1.3
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
66
62
70
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
80
80
100
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
800
800
800
Rack position
R1-1.3
Boost pressure
kPa
10.7
9.4
12
Boost pressure
mmHg
80
70
90
Boost compensator adjustment_02
Pump speed
r/min
800
800
800
Rack position
R1(12.8)
Boost pressure
kPa
20
20
20
Boost pressure
mmHg
150
150
150
Timer adjustment
Pump speed
r/min
920--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
870
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1400
Advance angle
deg.
2
1.5
2.5
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
(4)Boost compensator stroke: BCL
----------
T1=J64 BCL=1.3+-0.1mm
----------
----------
T1=J64 BCL=1.3+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=100mm
----------
a=26.5deg+-5deg b=42deg+-3deg
----------
aa=100mm
----------
a=26.5deg+-5deg b=42deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
----------
aa=36mm
----------
a=20deg+-5deg b=40deg+-5deg
----------
aa=36mm
----------
a=20deg+-5deg b=40deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(30deg)
----------
----------
a=(30deg)
Information:
1. Remove the bolts that hold the cylinder head assembly to the cylinder block.
To prevent damage to the two cylinder head-to-cylinder block dowels, keep the cylinder head assembly level during removal and installation.
2. Fasten a hoist to the cylinder head assembly as shown. Carefully remove the cylinder head assembly from the cylinder block. Remove the cylinder head gasket. The weight of the cylinder head assembly can range from 50 to 75 kg (110 to 165 lb). The following steps are for the installation of the cylinder head assembly.3. Be sure the mating surface of the cylinder head assembly and the cylinder block are thoroughly clean.4. Put a new cylinder head gasket in position on the cylinder block. Be sure the head gasket is dry. Fasten a hoist to the cylinder head assembly, and put it in position on the cylinder block.
3114 Cylinder Head Tightening Sequence
3116 Cylinder Head Tightening Sequence Bolts (1) are large diameter bolts (M20). Bolts (2) are small diameter bolts (M10).5. Apply clean engine oil on the threads of the cylinder head assembly mounting bolts.6. Install the bolts that hold the cylinder head assembly to the cylinder block, and tighten them as follows: a. Tighten the large diameter bolts in the number sequence shown to a torque of 150 15 N m (110 11 lb ft).b. Tighten the large diameter bolts in the number sequence shown to a torque of 435 20 N m (320 15 lb ft).c. Retorque the large diameter bolts in the number sequence shown to a torque of 435 20 N m (320 15 lb ft).d. Tighten the small diameter bolts in the number sequence shown to a torque of 55 7 N m (41 5 lb ft).End By:a. install unit fuel injectorsb. install fuel control linkagec. install rocker arm assemblies and push rodsd. install inlet manifolde. install exhaust manifoldf. install fuel filter and fuel filter base
To prevent damage to the two cylinder head-to-cylinder block dowels, keep the cylinder head assembly level during removal and installation.
2. Fasten a hoist to the cylinder head assembly as shown. Carefully remove the cylinder head assembly from the cylinder block. Remove the cylinder head gasket. The weight of the cylinder head assembly can range from 50 to 75 kg (110 to 165 lb). The following steps are for the installation of the cylinder head assembly.3. Be sure the mating surface of the cylinder head assembly and the cylinder block are thoroughly clean.4. Put a new cylinder head gasket in position on the cylinder block. Be sure the head gasket is dry. Fasten a hoist to the cylinder head assembly, and put it in position on the cylinder block.
3114 Cylinder Head Tightening Sequence
3116 Cylinder Head Tightening Sequence Bolts (1) are large diameter bolts (M20). Bolts (2) are small diameter bolts (M10).5. Apply clean engine oil on the threads of the cylinder head assembly mounting bolts.6. Install the bolts that hold the cylinder head assembly to the cylinder block, and tighten them as follows: a. Tighten the large diameter bolts in the number sequence shown to a torque of 150 15 N m (110 11 lb ft).b. Tighten the large diameter bolts in the number sequence shown to a torque of 435 20 N m (320 15 lb ft).c. Retorque the large diameter bolts in the number sequence shown to a torque of 435 20 N m (320 15 lb ft).d. Tighten the small diameter bolts in the number sequence shown to a torque of 55 7 N m (41 5 lb ft).End By:a. install unit fuel injectorsb. install fuel control linkagec. install rocker arm assemblies and push rodsd. install inlet manifolde. install exhaust manifoldf. install fuel filter and fuel filter base