101681-9030 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016819030 16700z5500

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101681-9030 1016819030

NISSAN-DIESEL 16700Z5500 16700z5500

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Service parts 101681-9030 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101068-3600

3. GOVERNOR 105461-0020

4. SUPPLY PUMP 105220-1910

5. AUTOM. ADVANCE MECHANIS 105622-0440

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4130

11. Nozzle and Holder 16600-Z5500

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105031-4290

14. NOZZLE 105015-3700

15. NOZZLE SET

Include in #1:

101681-9030 as INJECTION-PUMP ASSEMBLY

Include in #2:

104740-8890 as _

Cross reference number

ZEXEL 101681-9030 1016819030

NISSAN-DIESEL 16700Z5500 16700z5500

Zexel num

Bosch num

Firm num

Name

101681-9030

16700Z5500 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
FD6T *

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105100-4130

Nozzle 105015-3700

Bosch type code DLLA15S324ND90

Nozzle holder 105031-4290

Opening pressure MPa 21.6

Opening pressure kgf/cm2 220

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-626

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-4-2-6- 3-5

Pre-stroke mm 2.4 2.35 2.45

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 A

Rack position 11.7

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 77 74.7 79.3

Max. variation between cylinders % 0 -3 3

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 11.7

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 79.7 78.1 81.3

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_03

Adjusting point D

Rack position 7.2+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 12.5 10.7 14.3

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost compensator adjustment

Pump speed r/min 1000 1000 1000

Rack position 10.4

Boost pressure kPa 26.7 26.7 26.7

Boost pressure mmHg 200 200 200

Boost compensator adjustment_02

Pump speed r/min 1000 1000 1000

Rack position 11

Boost pressure kPa 44 41.3 46.7

Boost pressure mmHg 330 310 350

Boost compensator adjustment_03

Pump speed r/min 1000 1000 1000

Rack position 11.7

Boost pressure kPa 66.7 66.7 66.7

Boost pressure mmHg 500 500 500

Timer adjustment

Pump speed r/min 400+-50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1000

Advance angle deg. 1.5 1 2

Timer adjustment_03

Pump speed r/min 1600

Advance angle deg. 3 2.5 3.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Beginning of damper spring operation: DL (2)Boost compensator stroke: BCL
----------
DL=6.9-0.2mm BCL=1.3mm
----------

0000000901

F:Full load I:Idle
----------

----------
a=10.5deg+-5deg b=33.5deg+-3deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'P' at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(50deg)

Information:

Remove the single tie bolt (6) that is located in the top left corner of the pump by using Tooling (B). Refer to Illustration 7. Only remove the single tie bolt (6). Removing more bolts will result in damage to the pump.
Illustration 2 g01132938
(1) HEUI pump (2) Fuel transfer pump (4) Drive gear (5) 227-5904 O-Ring Seal (6) Tie Bolt (7) Bolts for the fuel transfer pump (8) Tie Bolts (9) Location for service bolt (12) 185-3241 O-Ring Seal
Replace tie bolt (6) with the temporary service bolt (9) that is provided in the service kit.Note: The service bolt that is provided in the kit has an undersized bolt head. The service bolt prevents the body of the HEUI pump from separating during service. Do not remove the service bolt until the fuel transfer pump has been completely reinstalled.
Tighten the service bolt (9) to 10 N m (7.4 lb ft) by using Tooling (C) .Note: Do not place an excessive torque on the service bolt. The aluminum housing of the pump could be damaged.
After installing the service bolt (9) in the top left location, remove the three bolts (7) that fasten the fuel transfer pump to the HEUI pump by using Tooling (A) .
Proceed by removing the remaining three tie bolts (8) by using Tooling (B) .
Separate the fuel transfer pump from the HEUI pump. Refer to Illustration 3.
Illustration 3 g01132944
(1) HEUI pump (2) Fuel transfer pump (9) Service bolt (10) Seals (11) SealInstalling the Fuel Transfer Pump onto the HEUI Pump
Install the two new 239-2402 Seals (10) on the back face of the HEUI pump (1). Refer to Illustration 4.
Illustration 4 g01077898
(1) HEUI pump (10) 239-2402 Seals
Install a new 179-8128 Seal (11) on the fuel transfer pump (2). Refer to Illustration 5. Use 1U-6396 O-Ring Assembly Compound in order to hold the seal in place during assembly. Ensure that the seal is completely seated.
Illustration 5 g01132957
(2) Fuel transfer pump (11) 179-8128 Seal
Do not remove the service bolt. Position the fuel transfer pump on the HEUI pump. Be sure to properly align the drive tang on the fuel transfer pump with the drive slot on the HEUI pump.Note: Align the drive tang of the fuel transfer pump so that the flat end is vertical. Refer to Illustration 5. Align the drive slot in the HEUI pump to a similar vertical orientation by using a flat head screwdriver. Refer to Illustration 6.
Illustration 6 g01132969
Note: Once the fuel transfer pump has been placed onto the HEUI pump, ensure that the face of the fuel transfer pump is flush with the face of the HEUI pump. If the pump faces are not flush, verify the alignment of the drive tang.
Install the three mounting bolts (7) for the fuel transfer pump (2). Tighten