101693-9120 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016939120 1671395112

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101693-9120 1016939120

NISSAN-DIESEL 1671395112 1671395112

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Cross reference number

ZEXEL 101693-9120 1016939120

NISSAN-DIESEL 1671395112 1671395112

Zexel num

Bosch num

Firm num

Name

101693-9120

1671395112 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
ND6 * 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 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 2.75 2.7 2.8

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 9

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 53.8 52.8 54.8

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.7

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 66.1 64.1 68.1

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point -

Rack position 7.6+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 9 7.8 10.2

Max. variation between cylinders % 0 -13 13

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_04

Adjusting point D

Rack position 12.6+-0. 5

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 84 84

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 800

Advance angle deg. 1.5 1 2

Timer adjustment_04

Pump speed r/min 1200

Advance angle deg. 4 3.5 4.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Damper spring setting: DL (2)Set the load lever's stop position so that R = aa (N = 0). (3)Excess fuel setting for starting: SXL
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DL=5.8-0.2mm aa=6.7mm SXL=10.9+0.2mm
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Speed control lever angle

F:Full speed
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----------
a=13deg+-5deg

0000000901

F:Full load I:Idle S:Stop (1)Rack position aa (pump speed bb r/min ) (2)Lever shaft standard
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aa=6.7mm bb=0r/min
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a=27deg+-3deg b=(14deg)+-3deg c=9.5deg+-5deg

Stop lever angle

N:Pump normal (1)Rack position = aa
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aa=7.2-0.2mm
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a=24deg+-5deg b=(48deg)+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(40deg)

Information:

Start By:a remove rack actuator packageb. remove fuel injection pumps 1. Remove rack (1) from the fuel pump housing. 2. Remove six lifters (2) from the fuel pump housing. Put identification marks on the lifters for installation purposes. 3. Remove camshaft (3) from the fuel pump housing. It may be necessary to use a soft hammer to push the camshaft out of the governor end of the fuel pump housing. 4. Remove races (4) and bearing (5) from the camshaft. Remove ring (6) if necessary. 5. Remove rack bearing (7) from both ends of the housing and dowel (8) if necessary. 6. Use tooling (A), and remove three camshaft bearings (9). 7. Remove the bolts, cover (10) and the gasket. 8. Remove pins (12), the seal and dowels (11) if necessary. Pins (12) must be pushed from the inside out.Assemble Fuel Injection Pump Housing
1. Clean and inspect all parts. Make a replacement of all parts that are worn or damaged. 2. Lubricate the seal with clean engine oil, and install pin (12). Pin (12) must protrude into the pump bore 2.15 .05 mm (0.85 .002 in.).3. Install dowel (11) so that it protrudes into the pump bore 1.93 .05 mm (0.76 .002 in.). 4. Install the gasket, cover (10) and the bolts. 5. Install the rack bearing with tooling (B). Install the bearing until the driver comes in contact with the plate. The bearing should be installed to a depth of 83.0 0.5 mm (3.27 .02 in.) from the fuel pump mounting face. 6. Measure the rack bearing (7). Dimension (X) must be 11.178 0.05 mm (.4400 .002 in.). Dimension (W) must be 12.767 0.058 mm (.5026 .0022 in.). 7. Install dowel (8). Dowel (8) must protrude 6.0 0.5 mm (.24 .02 in.) from the fuel pump housing face.8. Install the rear rack bearing with tooling (C) to a depth of 7.16 0.13 mm (.282 .005 in.) below the fuel pump housing surface. The inside diameter of the rear rack bearing must be 12.746 0.045 mm (.5018 .0017 in.). 9. User tooling (D), and install three camshaft bearings (9). Oil holes (13) in the camshaft bearings must be positioned 30° 3° above the horizontal centerline toward the engine side of the fuel pump housing. The outer bearings must be installed 1.0 0.5 mm (0.04 0.02 in.) below the surface marked (Z). The inner bearing must be installed 218.0 0.3 mm (8.58 .012 in.) below the front surface (Y). Diameter (XX) must be 68.339 0.038 mm (2.6905 0.015 in.) after assembly. 10. Install ring (6) races (4) and bearing (5) on the camshaft. 11. Lubricate can bearings (9) and cam shaft bearing journals with clean engine oil.12. Install camshaft (3) into the fuel pump housing.
The notch on the lifter must be in line with the dowel in the lifter bore. The lifter must slide up and