Information injection-pump assembly
ZEXEL
104741-4420
1047414420
NISSAN-DIESEL
167002S611
167002s611
Rating:
Cross reference number
ZEXEL
104741-4420
1047414420
NISSAN-DIESEL
167002S611
167002s611
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113orSAEJ967d
1404 Test oil ISO4113orSAEJ967d
Test oil temperature
degC
45
45
50
Nozzle
105780-0060
Bosch type code
NP-DN0SD1510
Nozzle holder
105780-2150
Opening pressure
MPa
13
13
13.3
Opening pressure
kgf/cm2
133
133
136
Injection pipe
157805-7320
Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-450
Inside diameter - outside diameter - length (mm) mm 2-6-450
Joint assembly
157641-4720
Tube assembly
157641-4020
Transfer pump pressure
kPa
20
20
20
Transfer pump pressure
kgf/cm2
0.2
0.2
0.2
Direction of rotation (viewed from drive side)
Right R
Right R
Injection timing adjustment
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
56.5
56
57
Difference in delivery
mm3/st.
4.5
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_02
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
50.3
46.8
53.8
Oil temperature
degC
48
46
50
Injection timing adjustment_03
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
55.1
51.6
58.6
Oil temperature
degC
50
48
52
Injection timing adjustment_04
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
56.5
55.5
57.5
Difference in delivery
mm3/st.
5
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_05
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
53.6
50.6
56.6
Oil temperature
degC
50
48
52
Injection timing adjustment_06
Pump speed
r/min
1800
1800
1800
Average injection quantity
mm3/st.
58.3
55.3
61.3
Oil temperature
degC
50
48
52
Injection quantity adjustment
Pump speed
r/min
2350
2350
2350
Average injection quantity
mm3/st.
18.1
16.1
20.1
Basic
*
Oil temperature
degC
52
50
54
Injection quantity adjustment_02
Pump speed
r/min
2500
2500
2500
Average injection quantity
mm3/st.
5
Oil temperature
degC
55
52
58
Injection quantity adjustment_03
Pump speed
r/min
2350
2350
2350
Average injection quantity
mm3/st.
18.1
15.6
20.6
Basic
*
Oil temperature
degC
52
50
54
Governor adjustment
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
8.9
6.9
10.9
Difference in delivery
mm3/st.
2
Basic
*
Oil temperature
degC
48
46
50
Governor adjustment_02
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
8.9
6.4
11.4
Difference in delivery
mm3/st.
2.5
Basic
*
Oil temperature
degC
48
46
50
Timer adjustment
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
90
75
110
Basic
*
Oil temperature
degC
48
46
50
Remarks
Full
Full
Timer adjustment_02
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
90
75
110
Oil temperature
degC
48
46
50
Speed control lever angle
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
0
0
0
Oil temperature
degC
48
46
50
Remarks
Magnet OFF at idling position
Magnet OFF at idling position
Speed control lever angle_02
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
5
Oil temperature
degC
48
46
50
Remarks
Magnet OFF at full-load position
Magnet OFF at full-load position
0000000901
Pump speed
r/min
1000
1000
1000
Overflow quantity with S/T ON
cm3/min
500
370
630
Oil temperature
degC
50
48
52
Remarks
Without S/T O-ring; S/T ON.
Without S/T O-ring; S/T ON.
Stop lever angle
Pump speed
r/min
1000
1000
1000
Pressure with S/T ON
kPa
618
579
657
Pressure with S/T ON
kgf/cm2
6.3
5.9
6.7
Pressure with S/T OFF
kPa
539
519
559
Pressure with S/T OFF
kgf/cm2
5.5
5.3
5.7
Basic
*
Oil temperature
degC
50
48
52
Stop lever angle_02
Pump speed
r/min
1000
1000
1000
Pressure with S/T OFF
kPa
539
510
568
Pressure with S/T OFF
kgf/cm2
5.5
5.1
5.9
Basic
*
Oil temperature
degC
50
48
52
Stop lever angle_03
Pump speed
r/min
1600
1600
1600
Pressure with S/T OFF
kPa
686
647
725
Pressure with S/T OFF
kgf/cm2
7
6.5
7.5
Oil temperature
degC
50
48
52
0000001101
Pump speed
r/min
1000
1000
1000
Timer stroke with S/T ON
mm
6.6
6.2
7
Timer stroke with S/T OFF
mm
5
4.8
5.2
Basic
*
Oil temperature
degC
50
48
52
_02
Pump speed
r/min
600
600
600
Timer stroke with S/T OFF
mm
1.8
1.3
2.3
Oil temperature
degC
50
48
52
_03
Pump speed
r/min
1000
1000
1000
Timer stroke with S/T ON
mm
6.6
6.1
7.1
Timer stroke with S/T OFF
mm
5
4.7
5.3
Basic
*
Oil temperature
degC
50
48
52
_04
Pump speed
r/min
1600
1600
1600
Timer stroke with S/T OFF
mm
8.3
7.8
8.8
Oil temperature
degC
50
48
52
_05
Pump speed
r/min
1900
1900
1900
Timer stroke with S/T OFF
mm
9
8.5
9.4
Oil temperature
degC
50
48
52
0000001201
Max. applied voltage
V
8
8
8
Test voltage
V
13
12
14
0000001401
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
32
31.5
32.5
Timer stroke TA
mm
4.2
4
4.4
Timer stroke variation dT
mm
0.8
0.8
0.8
Basic
*
Oil temperature
degC
50
48
52
_02
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
32
31
33
Timer stroke TA
mm
4.2
3.9
4.5
Timer stroke variation dT
mm
0.8
0.8
0.8
Basic
*
Oil temperature
degC
50
48
52
_03
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
20
17.5
22.5
Timer stroke TA
mm
3
2.5
3.5
Timer stroke variation dT
mm
2
2
2
Oil temperature
degC
50
48
52
Timing setting
K dimension
mm
3.3
3.2
3.4
KF dimension
mm
5.62
5.52
5.72
MS dimension
mm
0.9
0.8
1
Pre-stroke
mm
0.1
0.08
0.12
Control lever angle alpha
deg.
55.5
51.5
59.5
Control lever angle beta
deg.
36
31
41
Information:
When fuel has stopped flowing out, turn the crankshaft slightly in the reverse direction such that fuel flows out. Then, slowly turn the crankshaft clockwise again to more accurately verify the point at which fuel stops flowing out.
End of fuel flow(c) If the IT mark on the crankshaft pulley and the mark on the gear case are aligned when fuel stops flowing out the injection timing is normal.
Timing marks(3) Adjustment
(a) If the injection timing is out of specification, make adjustments by increasing or decreasing the thickness of the injection pump's mounting shim. A change of 0.1 mm in the shim thickness yields a change of approximately 1° in the injection timing.
Injection timing adjusting shim(b) Increasing the shim thickness retards the injection timing, and decreasing the shim thickness advances it. Shims come in 9 different thicknesses from 0.2 mm (0.008 in.) to 1.0 mm (0.039 in.) at intervals of 0.1 mm (0.004 in.). The thickness is not indicated on the shim, so any shim should be measured with a vernier caliper before being used.
Before using any shim, apply sealant to both sides to prevent oil leakage.
(c) After making adjustments, check the injection timing is correct.(d) Close the cock on the fuel filter, then fit the delivery valve spring and injection pipe in their original positions.
Adjusting injection timingAdjusting Idle Speed
(1) Preparation for Adjustment
(a) Warm up the engine unit the coolant reaches a temperature of 60°C (140°F) or higher.(b) Make sure the valve clearances, injection timing, and injectors are normal.(2) Adjusting Low-Idle Speed
Loosen the locknut on the idling set bolt, turn the bolt to achieve the specified low-idle speed (1000 25min-1), then tighten the lock nut to hold the bolt in that position.(3) Adjusting No-Load Maximum Speed
Loosen the lock nut on the high-speed set bolt, turn the bolt to achieve the specified no-load maximum speed (2600 +30-10 min-1), then tighten the lock nut to hold the bolt in that position.
Adjusting idle speedAdjusting Fan Belt Tension
(1) Press the fan belt with the specified force mid-way between the alternator pulley and crankshaft pulley, and observe the extent of deflection.Unit: mm (in.) (2) If the extent of deflection is out of specification, loosen the adjusting bolt and adjust the fan belt tension by moving the alternator. Retighten the adjusting bolt securely.
Adjusting fan belt tensionRunning in the Engine
After an overhaul, the engine should be tested and inspected on a dynamometer. This operation serves to run in the engine's major moving parts.Starting the Engine
(1) Before starting the engine, check the coolant, engine oil and fuel levels and bleed all air out of the fuel and cooling systems.(2) Without supplying fuel to the engine, crank the engine for about 10 seconds to permit oil to circulate through it.(3) Move the speed control lever slightly in the fuel-increase direction. (Do not move the lever to the full-injection position.) Then, turn the starter switch to the START position to start the engine.(4) Once the engine has started, set it to the low-idle speed using the speed control lever.Inspection after
End of fuel flow(c) If the IT mark on the crankshaft pulley and the mark on the gear case are aligned when fuel stops flowing out the injection timing is normal.
Timing marks(3) Adjustment
(a) If the injection timing is out of specification, make adjustments by increasing or decreasing the thickness of the injection pump's mounting shim. A change of 0.1 mm in the shim thickness yields a change of approximately 1° in the injection timing.
Injection timing adjusting shim(b) Increasing the shim thickness retards the injection timing, and decreasing the shim thickness advances it. Shims come in 9 different thicknesses from 0.2 mm (0.008 in.) to 1.0 mm (0.039 in.) at intervals of 0.1 mm (0.004 in.). The thickness is not indicated on the shim, so any shim should be measured with a vernier caliper before being used.
Before using any shim, apply sealant to both sides to prevent oil leakage.
(c) After making adjustments, check the injection timing is correct.(d) Close the cock on the fuel filter, then fit the delivery valve spring and injection pipe in their original positions.
Adjusting injection timingAdjusting Idle Speed
(1) Preparation for Adjustment
(a) Warm up the engine unit the coolant reaches a temperature of 60°C (140°F) or higher.(b) Make sure the valve clearances, injection timing, and injectors are normal.(2) Adjusting Low-Idle Speed
Loosen the locknut on the idling set bolt, turn the bolt to achieve the specified low-idle speed (1000 25min-1), then tighten the lock nut to hold the bolt in that position.(3) Adjusting No-Load Maximum Speed
Loosen the lock nut on the high-speed set bolt, turn the bolt to achieve the specified no-load maximum speed (2600 +30-10 min-1), then tighten the lock nut to hold the bolt in that position.
Adjusting idle speedAdjusting Fan Belt Tension
(1) Press the fan belt with the specified force mid-way between the alternator pulley and crankshaft pulley, and observe the extent of deflection.Unit: mm (in.) (2) If the extent of deflection is out of specification, loosen the adjusting bolt and adjust the fan belt tension by moving the alternator. Retighten the adjusting bolt securely.
Adjusting fan belt tensionRunning in the Engine
After an overhaul, the engine should be tested and inspected on a dynamometer. This operation serves to run in the engine's major moving parts.Starting the Engine
(1) Before starting the engine, check the coolant, engine oil and fuel levels and bleed all air out of the fuel and cooling systems.(2) Without supplying fuel to the engine, crank the engine for about 10 seconds to permit oil to circulate through it.(3) Move the speed control lever slightly in the fuel-increase direction. (Do not move the lever to the full-injection position.) Then, turn the starter switch to the START position to start the engine.(4) Once the engine has started, set it to the low-idle speed using the speed control lever.Inspection after