Information injection-pump assembly
ZEXEL
101607-9680
1016079680
NISSAN-DIESEL
16713Z6516
16713z6516
Rating:
Service parts 101607-9680 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-Z6003
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/22.6{230}
14.
NOZZLE
Cross reference number
ZEXEL
101607-9680
1016079680
NISSAN-DIESEL
16713Z6516
16713z6516
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
105780-8260
Bosch type code
9 430 610 133
Nozzle
105780-0120
Bosch type code
1 688 901 990
Nozzle holder
105780-2190
Opening pressure
MPa
18
Opening pressure
kgf/cm2
184
Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
131424-8921
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
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
Direction of rotation (viewed from drive side)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-4-2-6-
3-5
Pre-stroke
mm
3.7
3.65
3.75
Beginning of injection position
Governor side NO.1
Governor 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
800
800
800
Average injection quantity
mm3/st.
95
93.4
96.6
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
Z
Rack position
9.5+-0.5
Pump speed
r/min
280
280
280
Average injection quantity
mm3/st.
12
11
13
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
800
800
800
Average injection quantity
mm3/st.
95
94
96
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.9
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
100.5
96.5
104.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
125
125
135
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
970--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
920
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
(1000)
Advance angle
deg.
1.5
1
2
Timer adjustment_04
Pump speed
r/min
1160
Advance angle
deg.
1.5
1
2
Timer adjustment_05
Pump speed
r/min
1450
Advance angle
deg.
7
6.5
7.5
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=L27
----------
----------
T1=L27
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=36mm
----------
a=6.5deg+-5deg b=(42deg)+-3deg
----------
aa=36mm
----------
a=6.5deg+-5deg b=(42deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)No return spring
(2)Use the hole at R = aa
----------
aa=32mm
----------
a=10deg+-5deg b=40deg+-5deg
----------
aa=32mm
----------
a=10deg+-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=(80deg)
----------
----------
a=(80deg)
Information:
The 169-3374 Injector Sleeve Removal Group is used to remove the brass injector sleeves on 3176 and 3176B Engines, only. This tool group is used with the 9U-6860 Sleeve Replacement Group . The tool group eliminates the tapping and threading operation of the current 9U-6860 Sleeve Replacement Group . The benefits of this method of sleeve removal are easier sleeve removal and little debris that could enter the engine. This tool group uses a crimping die and captured stud similar to the current 3100 Sleeve Removal Tool. This tool group can be used with the cylinder head either on or off the engine.Additional Contact Information
For additional product support questions concerning this tool, contact the Dealer Service Tools Hotline at:USA: 1-800-542-8665, Option 1International: 1-309-578-7372Injector Sleeve Removal
Remove the rocker arms from the cylinder being repaired.
Remove the injector.
Illustration 4 g02888499
Put Sleeve Stud (3) into Injector Sleeve
Drop 142-8280 Sleeve Stud (3) into the injector sleeve and ensure that stud is resting at the bottom of the injector sleeve. The flat disc part of the sleeve stud should be below the top edge of the brass sleeve.
Illustration 5 g02888500
Insert Crimping Swage (9) Into Bore And Over Sleeve Stud (3)
Apply a light coating of grease to the inside cutting edge of crimping swage (9) and insert into the injector bore. Make sure that the tool is resting on the top edge of the brass sleeve by turning or "wiggling" slightly. It is possible for the tool to rest on the casting ledge (indicated by the arrow) in the cylinder head. The threads of sleeve stud (3) should go into the center hole of crimping swage (9), as shown in Figure 5.
Illustration 6 g02888508
Drive Crimping Swage (9) Down Into Injector Sleeve
Using a large hammer, strike the top of crimping swage (9) firmly and squarely. Drive down into the injector bore until the bottom slot is level with the top deck of the cylinder head, as shown in Figure 6.
Illustration 7 g02888509
Remove Driving Swage (9) With Crows Foot Pry Bar (12)
Remove the crimping swage from the injector bore. If the tool is stuck in the bore, use a crows foot pry bar (12) in the slot to work out the tool. Many times there will be a small amount of brass caught between crimping swage (9) and the injector bore causing the tool to stick. When the tool is removed, the top of the brass sleeve should be rolled over, trapping sleeve stud (3) inside the injector sleeve.Note: The sharp edge of crimping swage (9) must remain sharp and free of nicks or damage. This tool may be resharpened only on the inside cutting edge. Any sharpening procedure that reduces the OD of the cutting edge will result in poor tool performance and tool sticking.
Illustration 8 g02888517
Insert Sleeve Jaw (4)
Insert 151-4833 Sleeve Jaw (4) into the injector bore. The sharp edge of the sleeve jaw is designed to lock the rolled-over brass material between the sleeve stud and the sleeve jaw. The sleeve stud is then prevented from
For additional product support questions concerning this tool, contact the Dealer Service Tools Hotline at:USA: 1-800-542-8665, Option 1International: 1-309-578-7372Injector Sleeve Removal
Remove the rocker arms from the cylinder being repaired.
Remove the injector.
Illustration 4 g02888499
Put Sleeve Stud (3) into Injector Sleeve
Drop 142-8280 Sleeve Stud (3) into the injector sleeve and ensure that stud is resting at the bottom of the injector sleeve. The flat disc part of the sleeve stud should be below the top edge of the brass sleeve.
Illustration 5 g02888500
Insert Crimping Swage (9) Into Bore And Over Sleeve Stud (3)
Apply a light coating of grease to the inside cutting edge of crimping swage (9) and insert into the injector bore. Make sure that the tool is resting on the top edge of the brass sleeve by turning or "wiggling" slightly. It is possible for the tool to rest on the casting ledge (indicated by the arrow) in the cylinder head. The threads of sleeve stud (3) should go into the center hole of crimping swage (9), as shown in Figure 5.
Illustration 6 g02888508
Drive Crimping Swage (9) Down Into Injector Sleeve
Using a large hammer, strike the top of crimping swage (9) firmly and squarely. Drive down into the injector bore until the bottom slot is level with the top deck of the cylinder head, as shown in Figure 6.
Illustration 7 g02888509
Remove Driving Swage (9) With Crows Foot Pry Bar (12)
Remove the crimping swage from the injector bore. If the tool is stuck in the bore, use a crows foot pry bar (12) in the slot to work out the tool. Many times there will be a small amount of brass caught between crimping swage (9) and the injector bore causing the tool to stick. When the tool is removed, the top of the brass sleeve should be rolled over, trapping sleeve stud (3) inside the injector sleeve.Note: The sharp edge of crimping swage (9) must remain sharp and free of nicks or damage. This tool may be resharpened only on the inside cutting edge. Any sharpening procedure that reduces the OD of the cutting edge will result in poor tool performance and tool sticking.
Illustration 8 g02888517
Insert Sleeve Jaw (4)
Insert 151-4833 Sleeve Jaw (4) into the injector bore. The sharp edge of the sleeve jaw is designed to lock the rolled-over brass material between the sleeve stud and the sleeve jaw. The sleeve stud is then prevented from