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EE14E-11162
SERVICE MANUAL
VRZ
WARNINGS
The following definitions and warning signs are used in this service manual. These are extremely important to safe operation. Important points are described to prevent bodily injury and property damage. They must be fully understood before beginning VRZ maintenance. CAUTION!! CAUTION Improper maintenance can result in injury and property damage.
MEANINGS OF MARKS
The following marks are used in this service manual to facilitate correct VRZ maintenance. Advice Note Procedures that must be performed to enable the best possible VRZ maintenance. Information assisting in the best possible VRZ maintenance.
FOREWORD
This service manual describes the disassembly, inspection, reassembly and adjustment of the VRZ (radial plunger system position-control distributor type fuel injection pump). Refer to the separate service manuals listed below to facilitate VRZ type injection pump maintenance. This manual is intended for use by vehicle maintenance technicians or persons with an adequate knowledge of injection pumps. The contents of the manual, including illustrations, drawings and specifications were the latest available at the time of printing. The right is reserved to make changes in specifications and procedures at any time without notice. BOSCH K.K. Sales Automotive Aftermarket Division
Service manual VRZ Construction and Operation INJECTION PUMP TEST BENCH 10NP & 20 NP, Operation CONTINUOUS MEASURING DEVICE ZCM & ZCD, Operation CONTROLLER ASSEMBLY MC-02, FOR VRZ & COVEC-F WITH EEP-ROM, Operation MC-02 TESTER SOFTWARE, ADJUSTMENT AND INSPECTION DATA, FOR VRZ AND COVEC-F WITH EEP-ROM, Installation ECU ASSEMBLY, ADJUSTMENT AND INSPECTION DATA, FOR VRZ AND COVEC-F WITH EEP-ROM, Installation
CONTENTS
Page SERVICE PRECAUTIONS .................... 1 SPECIAL TOOLS ................................. 2 1. DISASSEMBLY, INSPECTION AND REASSEMBLY TOOLS .......................... 2 2. ADJUSTMENT TOOLS ........................... 9 DISASSEMBLY ................................... 15 1. 2. 3. 4. PREPARATION .................................... 15 EXPLODED VIEW ................................ 15 ENGINE DRIVE GEAR REMOVAL....... 16 DISASSEMBLY ..................................... 19 COMPONENT INSPECTION .............. 29 1. PREPARATION .................................... 29 2. INSPECTION ........................................ 30 GEAR REASSEMBLY ........................ 38 REASSEMBLY .................................... 42 1. REASSEMBLY ...................................... 42 2. PRE-STROKE ADJUSTMENT ............. 52 ADJUSTMENT .................................... 68 1. ADJUSTMENT CONDITIONS .............. 68 2. CONTROLLER UNIT CONTROLS ....... 72 3. PUMP ADJUSTMENT TOOL FLOW CHART ...................................... 75 4. PUMP ADJUSTMENT TOOL MONITOR SCREEN ............................. 76 5. PUMP ADJUSTMENT TOOL MONITOR SCREEN OUTLINE ............ 77 6. MANUAL OPERATION DISPLAY ......... 78 7. WORKSHOP DISPLAY ........................ 79 8. ADJUSTMENT ...................................... 80 9. MANUAL OPERATION (SECOND TIMING ADJUSTMENT)...... 99 Page INSPECTION .................................... 102 TIGHTENING TORQUES ................. 111 PART NUMBER EXPLANATION ..... 112 1. INJECTION PUMP ASSEMBLY NUMBER ............................................ 112 2. BOSCH TYPE NUMBER .................... 112
Injection pump
P-VRZR- 320
GE actuator
When carrying the injection pump, hold the pump by the bottom of the pump body.
CAUTION
Never hold the pump by the GE actuator or the harnesses. Holding the pump by these components may result in damage or injury.
Wire harness Pump body
P-VRZR- 321
GE actuator
Injection pump
When cleaning the injection pump, do not clean the GE actuator, the harnesses, or the harness connectors using fuel oil. Use only clean waste cloth.
P-VRZR- 323
-1-
SPECIAL TOOLS 1. DISASSEMBLY, INSPECTION AND REASSEMBLY TOOLS [1] Tool use locations
20 21 18 31 30
19 34 33 22 7 24 27
32 10
6 26 29 13 8 15
11
14
12 37 28 23 3, 4 2 5 25 36
16
1 17 35
P-VRZR- 324
-2-
157944-8521 9 681 610 317 Universal vise 157945-2020 9 681 610 812 Bracket 157944-7100 9 681 610 340 Bracket 157944-7200 9 681 610 797 Bracket 010010-2220 9 442 612 366 Bolt 157913-7000 0 986 612 682 Socket wrench 157928-4320 9 442 612 367 Feed pump holder 157914-3600 9 681 610 678 Socket wrench 157928-4000 9 442 612 368 Oil seal guide 157928-4120 9 442 612 299 Extractor 157829-3520 9 681 610 171 Measuring device
105782-4540 9 680 610 095 Measuring device 157847-0820 9 442 612 370 Coupling 157915-9820 9 681 610 687 Holder 157915-9201 9 681 610 684 Bit
-3-
SPECIAL TOOLS
Key no 30
RBAJ part no
Bosch part no
Part name
Qty 1
31 32 33 34 35 36 37
157928-4800 9 442 612 302 Plate 157917-4920 9 681 610 711 Wrench 157977-8000 9 681 610 829 Adapter 026512-1640 9 421 617 041 Gasket 157971-0500 9 443 613 408 Clip 157924-8520 9 681 611 028 Base 157928-4400 9 442 612 371 Pliers
1 1 1 3 1 1 1
For temporarily holding feed pump For turning auxiliary gear For inlet piping For inlet piping For fixing plunger Stand for installing drive gear For removing and installing drive gear snapring
-4-
SPECIAL TOOLS
-5-
SPECIAL TOOLS
46
25
75
-6-
SPECIAL TOOLS
-7-
SPECIAL TOOLS
-8-
9 8
1 7
P-VRZR- 325
-9-
1 688 010 129 Fixing stand 9 442 612 278 Injection pipe 9 443 612 974 Joint assembly
Includes injection tubing from nozzle assembly to cooling unit and from cooling unit to flow meter
Joint assembly
With tubes. Used together with adapter below. The joint assembly RBAJ part no. 157641-6820 (key no. 3 in the table above) can also be used instead of this tool.
Adapter
Note: Center height is the height from the center of the pump test benchs flywheel to the drive stand.
- 10 -
SPECIAL TOOLS
11
M10X1.0
7.
8.
- 11 -
1-2: 157966-3720 (9 443 613 456) 1-3: 157966-3820 (9 443 613 457) 1-4: 157966-3920 (9 443 613 458)
Note: Key number 1 (RBAJ part no.105782-8360, Bosch part no. 9 680 610 209) enables adjustment of both VRZ and COVEC-F pumps. With the VRZ, however, only key numbers 1-1 (RBAJ part no. 157966-4020, Bosch part no. 9 443 613 446) and 1-3 (RBAJ part no. 157966-3820, Bosch part no. 9 443 613 457) are necessary. Adjustment controller assembly part table (for VRZ)
Key no 1-1 1-1-1 1-1-2 1-1-3 1-1-4 1-1-5 1-1-6 1-1-7 1-1-8 1-1-9 1-3 RBAJ part no 157966-4020 157966-4120 157966-4420 157966-4520 157966-4620 157966-4720 157966-4820 157966-4920 157966-5020 157966-5100 157966-3820 Bosch part no Part name Qty 1 1 1 1 1 1 1 1 1 1 1 Checker assy Power supply (Japan, USA) Power supply (EC) PC: COM1 ~ MC-02 PC: COM2 ~ MC-02 FCV GND harness Controller-Pump GE Controller-Pump ROM Software (Overseas Ver.) & (Calibration data) & Manual For Mitsubishi 4M41 engines Remarks
9 443 613 446 CONTROLLER ASSY 9 443 613 447 Controller unit 9 443 613 448 Wire harness 9 443 613 449 Wire harness 9 443 613 450 Wire harness 9 443 613 451 Wire harness 9 443 613 452 Wire harness 9 443 613 453 Main harness 9 443 613 454 Main harness 9 443 613 455 CD-ROM 9 443 613 457 ECU assembly
- 12 -
SPECIAL TOOLS
1-1
1-1-1
1-1-2
1-1-3
1-1-4
1-1-5
1-1-6
2000
2000 1000
1-1-7
1-1-8
1-1-9
2000 2990
- 13 -
SPECIAL TOOLS
1-3
9 443 613 460 Intermediate harness 9 443 613 462 Intermediate harness
1. 157966-5720
(9 443 613 460) Intermediate harness (4M41)
2.
200 1100
- 14 -
DISASSEMBLY 1. PREPARATION
Clean the outside of the injection pump before disassembly, removing all grease and dirt. Drain the fuel oil from the pump. Keep the work bench and workshop clean and tidy. Before beginning disassembly, record performance data for later reference to facilitate the diagnosis of malfunctions and defects, if any, in the pump. Lay out the disassembled parts neatly and sequentially on the work bench, labelling them if necessary, to facilitate later reassembly. Prepare a container of clean fuel oil for plungers, delivery valves and other precision parts.
2. EXPLODED VIEW
153 161 65 150 150/8 152 151 121 37 35 948 949 110 111 112 50 949 55 56 50 50 51 53 60 16 25 20 82 931 930 15 80/8 80 920 27 26 810S 856S 925 923 9 18 10 83 8 7 50 205 6 17 1 41 40 42 43 45 46 32 31 30 35 905 11 912 3 914 2 5 80/7 922 38 50 22 36 34 33 160 100 122 101 878S 130 120 66 956
955
61
62
54
P-VRZR- 326
- 15 -
DISASSEMBLY
Injection pump body
P-VRZR- 300
Bolt (M6x1)
(2) Install wrench B so that it can turn the two gears (ie, the main gear and the sub-gear) clockwise. (3) Turn the main gear and the sub-gear using wrench A until they are aligned. Then, insert a bolt through the two gears and tighten it u s i n g a t o r q u e w r e n c h . ( Ti g h t e n temporarily.)
Tool name Wrench A Part no 157917-4920 157917-4620 Remarks
Wrench B
P-VRZR- 301
Wrench B
Note: The drive gear is divided into the main gear and the sub-gear. Wrench B is used to prevent drive gear rotation. Wrench A is used to align the main gear and the sub-gear.
Bolt (M6x1)
(4) Remove wrenches A and B and the torque wrench from the drive gear. (5) Install wrench B so that the main gear and the sub-gear are in the center of wrench B. (6) Remove the bolt from the drive gear. (7) Align the main gear and the sub-gear using wrench A, then install the bolt and tighten to the specified torque. Specified torque: 9 ~ 13 Nm {0.9 ~ 1.3 kgfm}
Wrench B
P-VRZR- 318
- 16 -
DISASSEMBLY
(8) Remove wrench A.
Sub-gear
P-VRZR- 302
P-VRZR- 303
Bolt
(10) Assemble puller A in the gap between the drive gear and the bracket and loosely fix the bolts.
Tool name Part no Remarks Puller 157927-4500 Parts A and B
Puller A
P-VRZR- 304
P-VRZR- 305
- 17 -
DISASSEMBLY
Drive gear
(12) Tighten the puller bolt to remove the drive gear. Advice Hold the puller so that it does not drop when the gear is removed from the drive shaft.
Bolt
P-VRZR- 306
Drive shaft
P-VRZR- 307
Bracket
(14) Remove the nuts (at three locations). (15) Remove the bracket from the pump housing and then remove the O-ring.
Nuts (3)
O-ring
P-VRZR- 319
- 18 -
DISASSEMBLY
Remove overflow valve from here.
P-VRZR- 016
Bolts (2)
Universal vise
(2) Attach bracket A and bracket B to the universal vise (and fix temporarily). (3) Attach bracket C to bracket A and bracket B and tighten bracket As and bracket Bs bolts.
Tool name Universal vise Part no 157944-8521 157944-7100 157944-7200 157945-2020 010010-2220 M10x1.5 Remarks
Bracket A Bracket B
Bracket B Bracket C
P-VRZR- 017
Bracket C Bolt
Injection pump
Bracket C
P-VRZR- 309
(5) Remove the bracket bolts. (6) Remove the TCV harness connector.
Bracket bolts
P-VRZR- 310
- 19 -
DISASSEMBLY
Grommet Magnet valve Nut
P-VRZR- 020
Holder GE actuator
Bit
Holder Bit
GE actuator
(2) Remove the GE actuator. Advice Do not damage the ball pin (refer to the GE actuator on page 35).
P-VRZR- 022
Assemble the socket wrench to the regulating valve and then remove the regulating valve.
Tool name Socket wrench Part no 157913-7000 Remarks
P-VRZR- 023
- 20 -
Holder Bit
Remarks
Holder Bit
T30
P-VRZR- 024
TCV
Screwdriver
(2) Lift the TCV up a little and then insert a screwdriver into the gap to pry up and remove the TCV. Advice Do not damage the pump housing.
Pump housing
P-VRZR- 025
EEPROM
P-VRZR- 311
- 21 -
DISASSEMBLY
(2) Remove the TPS bolts.
TPS bolts (2) TPS
P-VRZR- 026
(3) Remove the TPS, the adjusting shim, the timer spring, the core rod and the TPS standard point shim. Advice Label the TPS standard point shim and the timer stroke adjusting shim to avoid mistaking them at reassembly.
Core rod
P-VRZR- 027
O-ring (large)
(4) Remove the timer cover and the O-rings (large and small).
Tool name Holder Bit Part no 157915-9820 157915-9600 T30 Remarks
Timer cover
O-ring (small)
Bit
Holder
P-VRZR- 028
- 22 -
DISASSEMBLY [7] CPV (constant pressure valve) holder and plug removal
(1) Loosen the CPV holders.
Socket wrench
Part no 157914-3600
Remarks
P-VRZR- 029
(2) Remove the CPV holders and the gaskets. Advice Line up the removed CPV holders in order to match the positions (A, B, C, D) on the distributor head from where they were removed.
P-VRZR- 030
P-VRZR- 031
(4) Remove the snapring and shim from the rotor shaft. Note: The shim is easier to remove after removing the distributor head assembly.
P-VRZR- 032
- 23 -
Advice If the distributor head is not loose, tap the sides lightly with a plastic hammer.
P-VRZR- 033
Distributor head
(2) Pull out the distributor head. Advice Do not drop the control sleeve. (3) Remove the washer.
P-VRZR- 034
Note: The force of the rotor shaft spring is acting on the forked plate. Use care during removal.
P-VRZR- 035
- 24 -
DISASSEMBLY
Rollers
(2) Remove the rotor shaft assembly and remove the rollers and roller shoes from the rotor shaft. Advice Do not drop the rollers or the roller shoes. Do not change the roller and roller shoe combinations. (3) Assemble the clip to prevent the plunger from dropping out of the rotor shaft assembly.
Tool name Clip Part no 157971-0500 Remarks
P-VRZR- 036
Insert the hooks pin into the snaprings hole and tighten the butterfly nut to pull out the snapring.
Tool name Hook Part no 157928-5820 Remarks
P-VRZR- 037
Remove the drive shaft, the washer and the seal ring.
- 25 -
DISASSEMBLY
Cam ring
Bearing
P-VRZR- 039
Slot Slider
Timer piston
P-VRZR- 040
Insert the holder into the bearing, push the holder button and remove the bearing.
Tool name Holder Part no 157928-3620 Remarks
P-VRZR- 041
- 26 -
DISASSEMBLY
Short torx bolt Holder Bit Pump housing Feed pump cover
P-VRZR- 042
Advice Use care because the torx bolt heads are easily broken. Note: Of the four torx bolts, only the three long ones are screwed into the feed pumps pump housing.
For feed pump Short torx bolt Long torx bolt Part no 149916-0400 (9 443 612 874) 149916-0300 (9 443 612 873) Remarks 1 3
(2) Remove the feed pump cover. (3) Remove the feed pump O-ring.
(4) Position the feed pump holder chamfer toward the GE actuator. (5) Push the feed pump holder into the pump housing, aligning the holder s two pins with the feed pump holes.
Tool name Feed pump holder Part no 157928-4320 Remarks
P-VRZR- 043
Pump housing
(6) Remove the pump housing assembled with the feed pump holder from bracket C.
Bracket C
P-VRZR- 044
- 27 -
DISASSEMBLY
(7) Hold the feed pump holder and turn the pump housing upside down. (8) Remove the feed pump holder with the feed pump from the bottom of the pump housing. Advice Remove the rotor assembly and the feed pump cover together with the feed pump holder.
P-VRZR- 045
(9) Position the plate on the cover and turn the feed pump holder right side up.
Plate
Tool name
Cover Feed pump Holder
Part no 157928-4800
Remarks
Plate
P-VRZR- 046
- 28 -
17 14 4 10 14 16 15
1 14 8 18 4 5
7 9 3 13 11 12 2
P-VRZR- 047
Repair kit part no: 149960-0020 (Bosch part no. 9 443 612 894)
Key no 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 RBAJ part no 149911-0800 149911-0000 149912-0200 149911-0100 149911-0200 149911-0300 146600-0000 146433-0100 146600-0500 149912-0800 161440-3800 161440-3700 149913-0100 139512-0500 146600-0600 146600-0700 149912-0500 029921-4020 Bosch part no 9 443 613 478 9 443 612 857 9 443 612 864 9 443 612 858 9 443 612 859 9 443 612 860 9 461 610 413 9 461 610 239 9 461 610 418 9 443 612 865 9 443 610 357 9 443 610 356 9 443 612 866 9 411 611 625 9 461 610 419 9 461 610 420 9 443 612 771 9 442 610 255 Part name O-ring O-ring Seal ring O-ring O-ring O-ring O-ring Gasket O-ring Seal ring O-ring O-ring Back-up ring Gasket O-ring O-ring Seal ring Cap Qty 1 1 1 2 1 1 2 6 1 1 1 1 1 6 1 1 1 6 Application FBB holder Feed pump Drive shaft TPS Timer cover Timer cover Head housing CPV assembly Head plug GE housing TCV (small) TCV (large) TCV In and out (t = 1.6) Regulating valve Regulating valve Magnet valve CPV holder
- 29 -
Pump housing
P-VRZR- 048
Pump housing
(2) Replace the pump housing if the timer piston cylinder is damaged or worn. (3) If the regulating valve is blocked with dirt, etc, clean it using compressed air. If it cannot be cleaned, replace the pump housing. Advice When replacing the pump housing, replace it with the service kit. The service kit contains a pump housing and a timer piston.
Timer piston cylinder
P-VRZR- 049
Remarks
Oil seal
Part no
Remarks
Extractor
Note: The collet, bar and pushrod (see next page) are part of the extractor.
Collet
P-VRZR- 051
- 30 -
COMPONENT INSPECTION
Press Bar Pushrod
(2) Insert the bar into the collet from the pump housing side. (3) Hold the pushrod against the bar and push it using a press to remove the oil seal.
Tool name Bar Pushrod Part no Remarks 157925-2800 For 25 dia shaft 157926-1000
Oil seal
Collet
P-VRZR- 052
(1) Apply wax sealant (L101; manufactured by NOK) to the outside surface of a new oil seal.
Tool name Guide Part no 157848-2300 Remarks
Oil seal
P-VRZR- 053
(2) Pressfit the new oil seal into the pump housing until it is level with the surface of the pump housing. Advice Do not apply excessive force when pressfitting the oil seal.
P-VRZR- 054
- 31 -
COMPONENT INSPECTION
(6) Replace the drive shaft assembly if there is any play between the rotor shafts ball pin and the drive shaft.
Ball pin
Rotor shaft
P-VRZR- 056
Radial plungers
(1) Replace the distributor head assembly if any of the rotor shaft assemblys sliding parts are peeling, gnawed or scorched. (2) Replace the washer with a new one if it is worn.
(1) Replace the cam ring if the cam ring pin is worn. (2) Replace the cam ring if there is any play between the cam ring pin and the timer slider.
Pin
Timer slider
P-VRZR- 058
(3) Replace the cam ring if the cam rings cam profile is peeling or scorched.
Cam ring
P-VRZR- 059
- 32 -
Slider
(1) Replace the piston if the outside surface is worn or scratched. (2) Replace the slider if it is worn. Advice When replacing the timer piston, replace it with the service kit. The service kit contains a pump housing and a timer piston.
Tool name Service kit Part no 149500-0420 (9 443 613 486) Remarks
P-VRZR- 060
Rotor shaft
Distributor head
P-VRZR- 061
Radial plungers
(2) Inspect the plungers. If they are worn or damaged, replace the distributor head assembly. (3) Inspect the rollers and the roller shoes. Replace them with new ones if they are worn, peeling, scorched or gnawed.
P-VRZR- 062
(4) Replace the distributor head assembly if there is any play between the cam rings plate and the links pin.
- 33 -
COMPONENT INSPECTION
(5) Assemble the GE actuator s ball pin to the control sleeve groove. If there is any play, replace the distributor head assembly.
Control sleeve
P-VRZR- 064
P-VRZR- 065
P-VRZR- 066
O-rings
Replace the regulating valve assembly if the piston inside the regulating valve is sticking. Advice Always replace the O-rings with new ones. Do not disassemble the regulating valve unless necessary.
Stopper
P-VRZR- 067
- 34 -
(1) Replace the magnet valve assembly if the armature is scorched or cracked. (2) Replace the magnet valve assembly if the spring is damaged or rusted. Advice Always replace the O-ring with a new one. (3) Check the magnet valve resistance and replace the magnet valve assembly if the resistance is not as specified.
Terminal nos 1 - GND Resistance ( ) 8.01.2 Ambient temperature (C) 235
GE actuator
Ball pin
[15] GE actuator
(1) Replace the GE actuator if the ball pin is worn or if the plating is damaged or peeling.
P-VRZR- 069
GE actuator
(2) Assemble the GE actuator s ball pin in the control sleeve groove and confirm that there is no play. If there is any play between the ball pin and the control sleeve, replace the GE actuator or the distributor head assembly or both.
Control sleeve
6 5 4 3 2 1
12 11 10
9 8 7
P-VRZR- 312
Terminal no. 1 2 3 4 5 6 7 8 9 10 11 12
Name FCV Blank Blank CSP (OSC) TCV (+) GE (+) TF (+) CSP (MDL) TCV (-) GE (-) TF (-) CSP (GND)
Remarks Black, magnet valve Yellow Red White Blue, fuel temperature (+) Red Black Green Grey, fuel temperature (-) Black
- 35 -
COMPONENT INSPECTION
(3) Measure the resistances between each of the terminals. Reference values:
Terminal nos 6 - 10 8 - 12 4-8 4 - 12 7 - 11 Resistance ( ) 0.710.25 5.90.3 5.90.3 11.80.6 2.00.6k Ambient temperature (C) 235 235 235 235 235
6 5 4 12 11 10
3 2 1
9 8 7
P-VRZR- 313
(1) Replace the TCV if the TCV or O-ring is scratched or worn. (2) Check the filter for dirt. If it is dirty, clean it using compressed air. Advice Do not twist or break the O-ring or backup ring.
Filter
P-VRZR- 073
TCV
P-VRZR- 074
(1) Replace the TPS if the inside of the TPS or the core rod is bent or damaged. (2) Replace the TPS is the timer spring is worn or the seats are not centered. (3) Measure TPS resistances. Reference values:
Terminal nos 1-3 2-3 Resistance ( ) 82.05.7 82.05.7 Ambient temperature (C) 2510 2510
5 6 3
Core rod
P-VRZR- 075
- 36 -
Np sensors
P-VRZR- 314
Advice When using a digital circuit tester, resistances cannot be measured unless you hold the minus probe against the No. 2 terminal and the plus probe against the No. 3 terminal.
(k)
Resistance
Resistance () 2
P-VRZR- 163
- 37 -
CAUTION
Individual parts of the main gear (key nos. 1/1 to 1/8) cannot be replaced. [This is because the pin (1/6) is pressfitted through the sub-gear (1/2) to the main gear (1/1), and disassembly is not possible once the drive gear has been assembled.] The pulse plate (key no. 2), however, can be reused or replaced. The drive gear is not assembled when supplied. The following describes the assembly procedure.
1/6 1/8
1/5
RBAJ part no 149931-1910 149931-2000 149931-1600 149931-1200 149931-1300 149931-1400 149917-1500 149931-0600 149917-1400
Bosch part no 9 443 613 479 9 443 613 480 9 443 613 481 9 443 613 482 9 443 613 483 9 443 613 484 9 443 613 485 9 443 612 889 9 443 612 878
Part name Main gear Sub-gear Snapring Spring Pin Pin Socket head bolt Pulse plate Bolt
Qty 1 1 1 1 2 1 1 1 4
P-VRZR- 328
- 38 -
GEAR REASSEMBLY
Pin
Sub-gear
Pin
(2) Fully pressfit the pin to the sub-gear. Advice Pressfit the pin to the face of the gear without the mark A.
Part name Pin Sub-gear Part no Remarks (Mitsubishi part no) 149931-1300 (ME204193) 149931-2000 (ME204370)
Back is stamped A
P-VRZR- 329
Racks (2)
Base
(3) Fix the base in a vise. (4) Install the racks to the base using the socket head bolts.
Tool name Base Part no Remarks The racks are 157924-8520 included with the base. Use the racks with 157917-4300 the '4M41' stamping.
Rack
P-VRZR- 330
(5) Align the main gear with the racks and attach it to the center of the base.
P-VRZR- 331
Pin
P-VRZR- 332
- 39 -
GEAR REASSEMBLY
Sub-gear
(7) Attach the sub-gear to the main gear. At this time, hook the sub-gear s pin to the spring.
Spring Pin
P-VRZR- 333
Wrench
(8) Align the wrench with the sub-gear s holes and attach it to the sub-gear.
Tool name Part no 157917-4920 Remarks Wrench
Sub-gear
P-VRZR- 334
Sub-gear
(9) Turn the wrench counterclockwise to align the main gear s teeth with the sub-gear s teeth. (10) Screw in the socket head bolt (SW5) to tighten the sub-gear to the main gear. Specified torque: 9 ~ 13 Nm {0.9 ~ 1.3 kgfm}
Part name Socket head bolt
P-VRZR- 335
CAUTION
Pliers Snapring Main gear
Socket head bolts cannot be reused. (11) Hold the snapring open using pliers and install it in the main gears snapring groove.
Tool name Pliers
Part name
Part no 157928-4400
Remarks
Base
P-VRZR- 336
Snapring
- 40 -
GEAR REASSEMBLY
(12) Remove the drive gear assembly from the base and pressfit the pin until it is level with the face of the sub-gear. Specified position: 0 ~ 1 mm from face of sub-gear
Part name Pin Part no Remarks (Mitsubishi part no) 149931-1400 (MF472404)
P-VRZR- 337
(13) Turn the drive gear assembly upside down, align it with the racks and attach it to the center of the base.
Base
P-VRZR- 338
(14) Align the pulse plates long hole with the drive gear s positioning pin and attach it to the drive gear.
Part name Pulse plate Part no Remarks (Mitsubishi part no) 149931-0600 (ME203076)
Base
P-VRZR- 339
(15) Screw in the bolts (SW7) and tighten the pulse plate to the drive gear. Specified torque: 4 ~ 5 Nm {0.4 ~ 0.5 kgfm}
Part name Bolts Part no (Mitsubishi part no) 149917-1400 (MF472404) Remarks 4; not reuseable
CAUTION
Bolts cannot be reused.
P-VRZR- 340
The above completes reassembly of the drive gear for the 4M41 model engine.
- 41 -
REASSEMBLY
The reassembly of the VRZ type injection pump is basically the reverse of the disassembly procedure. The following describes the standard reassembly procedure. Always replace gaskets and O-rings with new ones.
Advice Confirm that the blades grooves are positioned toward the inside. Blade and rotor orientation cannot be changed. The feed pumps liner is marked with an R for clockwise injection pump rotation or an L for counterclockwise injection pump rotation. Install the liner so that the applicable mark can be seen when the liner is viewed from the head side.
Pins
Cover
(1) Position the feed pump assembly and the cover on the feed pump holder. Assemble the holder pins in the feed pump holes (2).
Tool name Part no 157928-4320 Remarks Feed pump holder
Notch Chamfer
Notch
Feed pump
P-VRZR- 078
Advice Align the feed pump cover notch with the feed pump holder chamfer.
Notch
Pump housing
(2) Position the feed pump cover notch toward the GE actuator side and insert the feed pump assembly into the pump housing until the feed pump is contacting the housing. (3) Hold the feed pump holder so that it does not move and turn the pump housing upside down.
- 42 -
REASSEMBLY
(4) Attach the pump housing to bracket C and remove the feed pump holder.
Pump housing
Bolts (3)
Bracket C
P-VRZR- 080
Set screw
(5) Screw the set screw into the pump housing. (The set screw is used as a guide when positioning the feed pump cover.)
Tool name Set screw Part no 157928-4500 Remarks
Feed pump
(6) Assemble the feed pump O-ring to the feed pump. (Refer to page 29 for the O-ring key number.)
P-VRZR- 081
Set screw
Guide
(7) Align the feed pump cover hole with the set screw and assemble the cover to the feed pump. (8) Insert the guide into the feed pump.
Tool name Guide Part no 157928-4200 Remarks
P-VRZR- 082
- 43 -
REASSEMBLY
(10) Remove the set screw and install the other two torx bolts. (11) Tighten the four torx bolts uniformly. (One of the four torx bolts does not screw into the pump housing.) Specified torque: 3.0 ~ 4.0 Nm {0.3 ~ 0.4 kgfm}
For feed pump Short torx bolt
P-VRZR- 083
Holder Bit
Remarks 1 3
Remarks
Advice Move the rotor backward and forward and left and right with your finger and check that it moves smoothly. If it does not move smoothly, loosen the feed pump cover and then retighten it to the specified torque. (12) Insert the seal ring into the feed pump cover. Advice Be careful with the assembly orientation of the seal ring and ensure it is securely assembled to the feed pump cover.
Head side
Seal ring
P-VRZR- 084
(1) Assemble the holder to the bearing and press the holder button (to hold the bearing). (2) Install the bearing in the pump housing.
Tool name Holder Part no 157928-3620 Remarks
- 44 -
Slider
P-VRZR- 086
Pump housing
Timer piston
(2) Assemble the timer piston and slider in the pump housing. Advice Align the slider hole with the timer piston hole. The slider is assembled in the timer with the hole positioned toward the GE actuator side. Note: The timer piston s low pressure side is positioned toward where the Q adjustment ROM is installed.
Pump housing
P-VRZR- 088
- 45 -
Part no 157928-3620
Remarks
Holder
Spacer
Spacer
U-shaped ring
Bearing
Pump housing
P-VRZR- 090
Shim Key
(4) Assemble the shim and the feed pumps drive side key on the drive shaft. (5) Assemble the oil seal guide on the drive shaft thread.
Tool name Oil seal guide Part no 157928-4000 Remarks For 25 dia shaft
Drive shaft
Drive shaft
(6) Confirm that the seal ring is inserted into the feed pump cover (see bottom figure of page 44). (7) Align the drive shaft key with the feed pump rotor key groove and insert the drive shaft into the feed pump. Advice Insert the drive shaft gently into the feed pump while turning it clockwise and counter clockwise to align the key with the key groove.
P-VRZR- 092
- 46 -
REASSEMBLY
Plastic hammer
1 ~ 2 mm
; ;
Drive shaft
Inner cam
P-VRZR- 093
(8) Lightly tap the drive shaft using a plastic hammer to assemble the drive shaft with the end fully protruding from the drive side. Advice When tapping the drive shaft with the plastic hammer, ensure no burrs or dirt remain on the shaft. Insert the drive shaft so that the end of the drive shaft is 1 ~ 2 mm higher than the end of the inner cam (when viewed from above). After assembling the drive shaft, confirm that the shaft rotates smoothly.
P-VRZR- 094
Part no 157928-3120
Remarks
Advice Position the snapring on the clip with the convex face toward the clip.
Convex face
P-VRZR- 095
(3) Position the snapring in the drive shafts ring groove and push it straight down. (4) Remove the clip from the snapring and use the end of the clip to push the snapring fully into the groove. Advice Confirm that the snapring is fully inserted into the groove and that the drive shaft can be rotated.
P-VRZR- 096
- 47 -
Distributor head
Pump housing
P-VRZR- 097
Holder
(2) Install and tighten two diametrically opposed torx bolts of the four to install the distributor head. Specified torque: 10.0 ~ 14.0 Nm {1.0 ~ 1.4 kgfm}
Tool name Holder Bit Part no 157915-9820 157915-9600 T30 Remarks
P-VRZR- 098
(3) Attach the measuring device to the drive shaft. (4) Attach the dial gauge to the measuring device.
Tool name Measuring device Part no 105782-4530 Remarks
Drive shaft
P-VRZR- 099
Measuring device
Drive shaft
P-VRZR- 100
(5) Measure the drive shafts axial play. Specified value: 0.10.05 mm (with the head assembly installed) (6) If not as specified, select shims from the table on the following page and exchange the shims until the axial play is as specified. (Refer to page 49.) Advice If the axial play varies greatly from the specified value, repeat procedure [5] on page 46 and [6] on page 47.
- 48 -
REASSEMBLY
Shims
RBAJ part no 149602-0000 149602-0100 149602-0200 149602-0300 149602-0400 149602-0500 149602-0600 149602-0700 149602-0800 149602-0900 149602-1000 Bosch part no 9 443 612 809 9 443 612 810 9 443 612 811 9 443 612 812 9 443 612 813 9 443 612 814 9 443 612 815 9 443 612 816 9 443 612 817 9 443 612 818 9 443 612 819 Thickness (mm) 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40
Measuring device
(7) Remove the dial gauge. (8) Remove the measuring device handle and attach the extractor. (9) Screw in the extractor to remove the measuring device.
Tool name Extractor Part no 157926-2421 Remarks
Extractor
P-VRZR- 101
Distributor head
(10) Remove the torx bolts from the distributor head. (11) Remove the distributor head from the pump housing.
Pump housing
P-VRZR- 102
Snapring
P-VRZR- 103
- 49 -
REASSEMBLY
(3) Attach the adapter to the head and then attach the measuring device to the adapter.
Tool name
Measuring device
Head
Remarks
Rotor shaft
Adapter
P-VRZR- 104
Head
(4) Pull the rotor shaft fully to the left and set the dial gauge to the 0 position.
Measuring device
Dial gauge
P-VRZR- 105
Procedure 2
Head
Measuring device
Calculating the shim thickness (1) Push the rotor shaft fully to the right and measure the full stroke from the dial gauge. Advice The rotor shafts groove must not catch on the head.
Rotor shaft
Adapter
P-VRZR- 106
(2) Select a shim using the formula below. Shim thickness = full stroke 0.2 (mm)
RBAJ part no (key no. 53) 149720-0000 149720-0100 149720-0200 149720-0300 Bosch part no 9 443 612 851 9 443 612 852 9 443 612 853 9 443 612 854 Thickness (mm) 2.1 2.2 2.3 2.4
Shim
Snapring
P-VRZR- 107
(3) Install the selected shim and the snapring to the rotor shaft. (4) After inserting the shim, confirm that the stroke is as specified. If not as specified, repeat Procedure 1 and Procedure 2. Specified stroke: 0.20.1 mm
- 50 -
REASSEMBLY
(5) Remove the dial gauge and adapter from the head. (6) Remove the snapring.
Pump housing
TPS
P-VRZR- 108
(2) Assemble the O-rings (at two locations) and then assemble the high pressure side timer cover on the pump housing. Specified torque: 7.0 ~ 10.0 Nm {0.7 ~ 1.0 kgfm}
P-VRZR- 109
Bracket C
P-VRZR- 110
- 51 -
Fundamentally, pre-stroke is the amount of lift from the cams bottom dead center position to the beginning of pressure delivery position. With the VRZ pump, however, because it is not possible to measure the cam lift with the pump assembled, the cam angle is instead measured from the beginning of cam lift position to the beginning of pressure delivery position. The beginning of pressure delivery position can be changed by changing the phase (ie, the angle) between the cam link and the control sleeve, which are connected by the timing link shaft. Consequently, by changing the position of the link plate groove, we can change the phase of the cam link and the control sleeve to adjust the pre-stroke (ie, substituting the angle instead). Pre-stroke adjustment sequence (1) Attach the measuring device to the pump. (2) Align the measuring devices measuring terminal with the standard cylinder Bs cam position. (3) Find the cams bottom dead center position using the dial gauge, then zero the dial gauge. (4) Rotate the pump in the specified direction of rotation and set the cam lift to 0.70 mm using the dial gauge. (5) Set the 0 point using the KMA device to display cam lift as an angle. (6) Turn the pump back 10 in the direction opposite to the specified direction of rotation. Turn the pump 5 in the specified direction of rotation (to prevent backlash). (7) Confirm that the dial gauge displays 0 mm. (8) Using the KMA device, reset the 0 point. (Using the KMA device, begin cam lift.)
- 52 -
REASSEMBLY
Injection pump Flange
CAUTION
The pump test bench drive motor must be turned OFF. Injury or damage may result if the pump test bench drive motor is turned ON. (1) Temporarily attach the fixing stand to the pump test bench and attach the injection pump to the fixing stand.
Fixing stand
P-VRZR- 316
Part no
Remarks
(2) Align the key groove with the standard cylinder Bs pressure delivery cam position as shown at left.
Drive shaft key position for 4M41 model engine
P-VRZR- 111
Measuring terminal
Measuring device
P-VRZR- 317
(3) Align the drive shaft key groove and the measuring devices measuring terminal. Note: The pre-stroke can be measured on any cylinder. Because the pump is set at the standard cylinder B, however, measure the pre-stroke for this cylinder. If the drive shaft key groove and the measuring devices measuring terminal are not aligned, pre-stroke cannot be adjusted from cylinder B when the rotor shaft is assembled. (4) Install the pre-stroke measuring device. Specified torque: 10.0 ~ 14.0 Nm {1.0 ~ 1.4 kgfm}
Tool name Measuring device Part no 105782-4540 Remarks
Measuring device
Drive shaft
Advice Align the drive shafts key groove and the measuring devices measuring terminal with the drive shaft. Ensure the end of the measuring device is securely assembled to the drive shaft groove.
- 53 -
REASSEMBLY
(5) Assemble the key to the drive shaft. Align the coupling with the key, assemble it to the drive shaft and then fix it using the nut.
Tool name Coupling Part no Remarks 157847-0820 Shaft dia 25
Specified torque:
P-VRZR- 114
(6) Move the fixing stand to assemble the coupling teeth to the pump test bench drive coupling. Advice Ensure approximately 1 mm axial clearance between the coupling and the drive coupling.
Fixing stand
P-VRZR- 115
Flywheel
(7) Securely tighten the fixing stand installation bolts and nuts and the drive coupling socket head bolt to fix the injection pump to the pump test bench. (8) Turn the pump test bench flywheel using the lever to confirm that the injection pump rotates smoothly.
CAUTION
Lever
P-VRZR- 116
Remove the lever after operating the flywheel. Operating the test bench without removing the lever can cause serious injury and damage the test bench.
- 54 -
REASSEMBLY
Monitor display example
angle measurement
10
11
12
F1
F2
F3
F4
F5
F6
F7
F8
P-VRZR- 164
Flywheel
(2) Turn the pump test bench flywheel in the direction of pump rotation to find the standard cylinder s bottom dead center position on the measuring device dial gauge. (Refer to the data sheet for the standard cylinder.)
Dial gauge
P-VRZR- 118
(3) Zero the dial gauge. (4) Turn the flywheel in the direction of rotation so that the dial gauge reading is 0.7 mm.
Dial gauge
P-VRZR- 117
- 55 -
REASSEMBLY
Monitor display example
angle measurement
0.0
F1
F2
F3
F4
F5
F6
F7
F8
P-VRZR- 165
Flywheel
(5) Set the continuous measuring device as described below. Press F2 Press both shift keys (press both shift keys at the same time to activate angle control) the monitor will display the dialog position control unit error: control circuit open) Press Enter the monitor display will change to(---.-) Press F6 Select zero point setting Press Enter. (The pump test bench angle measurement is now set at 0.) (6) To absorb backlash, turn the flywheel back at least 10 and then set the angle measurement display at 355 (ie, turn the flywheel back 5). (7) Check that the dial gauge reading is 0mm. (8) Set the continuous measuring device as described below. Select zero point setting Press F6 Press Enter. (The pump test bench angle measurement is now set at 0.) Advice Do not alter the continuous measuring device angle measurement menu after this. Note: The beginning of cam lift position is now set. (9) Remove the measuring device.
P-VRZR- 119
Measuring device
P-VRZR- 120
- 56 -
REASSEMBLY
Pump housing
(10) Remove the TPS from the pump housing. (11) Remove the timer cover from the pump housing.
TPS
Timer cover
P-VRZR- 121
Forked plate marked G Replaced Replaced Replaced Do not replace (use the installed forked plate)*
Replaced Replaced
Holder
Bit
P-VRZR- 122
Spring
If the installed forked plate fork is worn, assemble a forked plate marked G. (Refer to the table on page 67.) Specified torque: 3.0 ~ 5.0 Nm {0.3 ~ 0.5 kgfm}
Rotor shaft
Clip
Part no 157915-9820
Remarks
Bit
P-VRZR- 123
157915-9301 T20
(2) Rotate the drive shaft so that the rotor shaft pin is positioned toward the GE actuator as shown at left. Note: The rotor shaft does not contact the forked pate. (3) Remove the clip from the rotor shaft.
Tool name Clip Part no 157971-0500 Remarks
(4) Assemble the radial plungers, the roller shoes and the rollers to the rotor shaft. (5) With the spring assembled to the rotor shaft, assemble the rotor shaft assembly to the drive shaft groove. Advice Do not drop the roller shoes or the rollers. - 57 -
REASSEMBLY
(2) Distributor head assembly reassembly (1) Assemble the O-ring on the distributor head. (2) Assemble the control sleeve in the distributor head. Advice The face with the larger chamfer is positioned toward the head.
Control sleeve
Head side
Large chamfer
Small chamfer
Distributor head
P-VRZR- 124
Pump housing
P-VRZR- 125
Torx bolts
Distributor head
Pump housing
P-VRZR- 126
(3) Assemble the distributor head assembly to the rotor shaft. (4) Tighten diagonally opposed torx bolts to loosely install the distributor head. Advice Do not tighten the distributor head assembly. Leave it loose. (5) Assemble the distributor head assembly to the pump housing. Advice Move the timer piston to align the forked plate groove with the distributor head assembly pin. (6) Move the timer piston and confirm that the control sleeve rotates, and then gradually tighten two diametrically opposed torx bolts. (7) If the timer piston does not move smoothly, loosen the torx bolts and repeat procedure (6) above. Note: If the timer piston does not move smoothly, the control sleeve will not move smoothly, the pin may not engage the plate when the head is tightened, and either the plate or the pin may be damaged. (8) Tighten the torx bolts until the distributor head assembly is securely tightened to the pump housing.
- 58 -
REASSEMBLY
(9) Install the other two torx bolts and then tighten all four torx bolts to the specified torque. Specified torque: 10.0 ~ 14.0 Nm {1.0 ~ 1.4 kgfm}
Tool name Holder
Bit
Remarks
Bit
T30
P-VRZR- 127
Snapring O-ring
(10) Assemble the shim and snapring to the rotor shaft. (11) Install the plug to the distributor head together with a new O-ring.
Shim Plug
P-VRZR- 128
(12) Tighten the plug using a hexagon wrench (SW14mm). Specified torque: 20.0 ~ 29.0 Nm {2.0 ~ 3.0 kgfm}
P-VRZR- 129
(3) CPV holder reassembly (1) Assemble the gaskets and CPV holders to the distributor heads cylinders A, C and D. Advice The CPV holders must be reassembled to the distributor head in their original positions A, C and D marked on the head. (2) Assemble the dummy holder and gasket to the distributor heads cylinder B.
Tool name
P-VRZR- 130
Part no 157845-9500
Holder
- 59 -
REASSEMBLY
CPV holder
Socket wrench
(3) Tighten the CPV holders using a socket wrench. Specified torque: 44.0 ~ 54.0 Nm {4.5 ~ 5.5 kgfm}
Tool name Socket wrench Part no 157914-3600 Remarks
P-VRZR- 131
(4) TCV (timing control valve) installation (1) Clean the TCV in clean light oil.
TCV
P-VRZR- 132
(2) Assemble the backup ring, the O-ring and the TCV in the pump housing. Advice Tw o b a c k u p r i n g s a r e r e m o v e d a t disassembly. One is reassembled at reassembly.
Backup ring
O-ring
P-VRZR- 133
Pump housing
(3) Push the TCV into the pump housing using your finger and fix it using the torx bolts. Specified torque: 7 ~ 10.0 Nm {0.7 ~ 1.0 kgfm}
Tool name Holder Bit Part no 157915-9820 157915-9600 T30 Remarks
TCV
Holder
Bit
P-VRZR- 134
- 60 -
REASSEMBLY
(5) Timer cover and TPS (timer piston sensor) reassembly (1) Assemble the timer cover and the small and large O-rings (new) to the high pressure side. (See below for the assembly procedure.)
Ti m e r cover
P-VRZR- 135
Small O-ring
Ti m e r cover
(2) Push the small O-ring securely into the pump housing using your finger. (3) Push the large O-ring securely into the timer cover using your finger and install the timer cover using the torx bolts. Specified torque: 7.0 ~ 10.0 Nm {0.7 ~ 1.0 kgfm}
Tool name Holder Bit Part no 157915-9820 157915-9600 T30 Remarks
P-VRZR- 136
TPS
O-ring
(4) Assemble the TPS standard point shim, the core rod, the timer spring and the timer stroke adjusting shim in the pump housing. Advice Do not mistake the assembly positions of the TPS standard point shim and the timer stroke adjusting shim. (5) Assemble the TPS to the pump housing. Advice Ensure the O-rings are not damaged.
(6) Secure the TPS to the pump housing using the torx bolts and a socket wrench (M6). Specified torque: 7.0 ~ 10.0 Nm {0.7 ~ 1.0 kgfm}
- 61 -
REASSEMBLY
Regulating valve Pump housing
(6) Regulating valve installation (1) Shake the regulating valve and confirm that the piston is moving (listen for a clicking sound). (2) Install the regulating valve in the pump housing. Advice Confirm that the regulating valve piston moves smoothly.
P-VRZR- 139
Socket wrench
(3) Tighten the regulating valve using the socket wrench. Specified torque: 10.0 ~ 13.0 Nm {1.0 ~ 1.3 kgfm}
Tool name Socket wrench Part no 157913-7000 Remarks
P-VRZR- 140
(7) GE actuator installation (1) Assemble the seal ring (new) to the GE actuator.
P-VRZR- 141
(2) Position the control sleeve groove toward the GE actuator and fix it in an intermediate position. Note: This facilitates GE actuator installation.
Rotor shaft
P-VRZR- 142
- 62 -
REASSEMBLY
GE actuator pin
P-VRZR- 143
GE actuator
P-VRZR- 144
(4) Move the GE actuator in an axial direction as shown by the arrow in the figure at left and confirm that the actuator moves smoothly. Advice Do not force the GE actuator. Forcing it may damage the seal ring. The GE actuator will not move if its pin is not inserted into the control sleeve groove. If it will not move, remove the GE actuator and again insert the pin into the groove. (5) Move the GE actuator fully toward the full side (ie, the head side). Advice If the GE actuator is positioned toward the drive shaft side, it may not be possible to measure the pre-stroke.
GE actuator
P-VRZR- 145
Holder
Bit
(6) Secure the GE actuator to the pump housing using the torx bolts. Advice Tighten diagonally opposed torx bolts gradually and uniformly to the specified torque. Specified torque: 7.0 ~ 10.0 Nm {0.7 ~ 1.0 kgfm}
Tool name Holder Part no 157915-9820 157915-9600 T30 Remarks
Pump housing
P-VRZR- 146
Bit
- 63 -
REASSEMBLY
Magnet valve assembly GE actuator Magnet valve O-ring Spring
(8) Magnet valve assembly installation (1) Install the magnet valve assembly to the GE actuator. Advice Ensure the filter is installed securely.
(2) Tighten the magnet valve assembly using a torque spanner. Specified torque: 20.0 ~ 25.0 Nm {2.0 ~ 2.5 kgfm}
P-VRZR- 148
(9) Pre-stroke adjustment (1) Connect the fuel hose to the injection pump using the adapter.
Tool name Adapter Gasket Part no 157977-8000 026512-1640 Remarks
Hose
P-VRZR- 149
Plugs
(2) Install plugs to where the distributor head and GE actuator overflow valves were removed. Advice Install any suitable plugs to maintain pump chamber air tightness.
P-VRZR- 150
- 64 -
REASSEMBLY
(3) Remove cylinder Bs delivery valve holder and assemble the pipe assembly to cylinder B.
Tool name
Cylinder B
Pipe assembly
Part no 157845-9520
Remarks
Pipe assembly
P-VRZR- 151
(4) Connect the direct current harness to the magnet valve. Advice Magnet valve supply voltage 12V specification: 12V
P-VRZR- 152
Injection pump
(5) Turn the pump test bench drive switch ON. (6) Supply test oil to the injection pump at the specified pressure (20.0 kPa {0.2 kgf/cm2}). Advice Leave the drive switch ON. Do not turn the drive switch OFF until pre-stroke adjustment has been completed.
P-VRZR- 153
Flywheel
(7) Turn the pump test bench flywheel about one turn in the specified direction of rotation using the lever and use the angle measurement display to confirm that it turns smoothly.
Lever
P-VRZR- 154
- 65 -
REASSEMBLY
(8) Turn the pump test bench flywheel using the lever and set the pump test bench angle measurement at the 0 position (ie, the beginning of cam lift position). Advice Confirm that test oil flows from the pipe assemblys overflow. Align the flywheel with the position set during Procedure [2] Setting the 0 point for pre-stroke adjustment on page 55.
P-VRZR- 155
Pipe assembly
Pipe assembly
(9) Turn the pump test bench flywheel slowly in the specified direction of rotation using the lever and read the angle measurement indication (ie, the pre-stroke) when test oil stops flowing from the pipe assembly overflow. Note: Test oil has stopped flowing when only 2 ~ 3 drops / second flow from the overflow.
CAUTION
P-VRZR- 156
Remove the lever after operating the flywheel. Operating the test bench without removing the lever can cause serious injury and damage the test bench. Advice Leave the drive switch ON. If the drive switch is turned OFF, angle measurement will stop. Stop test oil flow to the injection pump by turning the test oil cock OFF. (10) If the pre-stroke is not as specified, replace the forked plate and readjust. (Refer to the next page for forked plate specifications. Refer to page 57 for the replacement procedure.) Specified value: 2.50.5 Advice For clockwise rotation, if the value is larger than specified, select plates starting from A. If smaller, select plates working back from M. Note: Forked plate pre-strokes correspond to angles of rotation.
Cam ring
Forked plate
P-VRZR- 157
- 66 -
REASSEMBLY
Forked plates for 4 cylinders
RBAJ part no 149615-0001 149615-0101 149615-0201 149615-0301 149615-0401 149615-0501 149615-0601 149615-0701 149615-0801 149615-0901 149615-1001 149615-1101 149615-1201 Bosch part no 9 443 612 824 9 443 612 825 9 443 612 826 9 443 612 827 9 443 612 828 9 443 612 829 9 443 612 830 9 443 612 831 9 443 612 832 9 443 612 833 9 443 612 834 9 443 612 835 9 443 612 836 Stamping Pre-stroke variation () A B C D E F G H I J K L M -3.03 -2.50 -1.97 -1.43 -1.07 -0.54 0 0.54 1.07 1.43 1.97 2.50 3.03
CPV holder
(11) Remove the pipe assembly from cylinder B and replace it with the CPV holder. Replace the gasket at the same time.
Cylinder B
P-VRZR- 158
Plugs
(12) Tighten the CPV holder using a socket wrench. Specified torque: 44.0 ~ 54.0 Nm {4.5 ~ 5.5 kgfm}
Tool name Socket wrench Part no 157914-3600 Remarks
CPV holder
Socket wrench
P-VRZR- 159
- 67 -
Windows OS Clock speed Memory Hard disk Display Drive devices Additional devices
Note: Refer to the Installation Manual, MC-02 TESTER SOFTWARE, ADJUSTMENT AND INSPECTION DATA, Publication No. ED14E-11011, for details of personal computer settings and software installation procedures.
Injection tubes
P-VRZR- 390
- 68 -
ADJUSTMENT
(2) Fuel piping
Key no 1 1/1 1/2 1/3 1/4 1/5 1/6 1/7 RBAJ part no 157971-1020 157971-1100 026512-1640 029711-2180 157971-1000 017211-2010 157986-8100 026510-1340 Bosch part no Part name Qty 1 6 2 1 2 1 1 Remarks For VRZ overflow fuel piping For distributor head overflow For distributor head overflow For distributor head overflow For distributor head overflow For distributor head overflow For distributor head overflow For distributor head overflow 9 443 613 442 Piping assembly 9 443 613 443 Bolt 9 421 617 041 Gasket 9 442 610 444 Eye 9 443 613 444 Adapter 9 442 611 983 Hose clip 9 443 613 445 Hose 9 442 610 043 Gasket
Piping outline
Pressure gauge
- 69 -
Tool connection 232C cable Connection: cross connection (2 pin, 3 pin cross) (157966-4720) Tool connection 232C cable Connection: straight connection (157966-4620) Personal computer Intermediate harness (157966-2421) Dsub 9 pin Dsub 25 pin Intermediate harness (157966-5720) FCV GND harness (157966-4820)
Dsub 7 pin ROM harness (157966-5020) Dsub 9 pin To AC100V - AC120V or AC200V - 240V power source (157966-4420 or 157966-4520) VRZ and COVEC-F controller unit Main harness (157966-4920) Earth to injection pump or pump test bench P-VRZR- 392
PC COM2 COM1
ROM writer
ROM cable
ROM
Main cable
Injection pump
FCV switch Main power switch DC 24V Constant power supply DC 12V Constant power supply 0 Sub-switch Selector switch 1 2 3 4
ECU lamp
Main cable
FCV switch
Main cable
Power lamp
FCV switch
ECU lamp
WL (COVEC-F) ECU
P-VRZR- 395
- 70 -
Note: Where updating of adjustment data and inspection data is indicated, copy the data from the ESPI (ZW)s CD-ROM.
- 71 -
13
14
P-VRZR- 344
Key no 1 2 3 4 5 6 7 8 9
Name Pump side wire harness connection Pump side wire harness connection Pump side wire harness connection
Use and purpose For connecting harness for injection pump's harness connectors and GE controller. For connecting harness for injection pump's harness connectors and GE controller. For connecting harness for injection pump's harness connectors and GE controller.
FCV (magnet valve) ON / OFF Turns the FC V (magnet valve) ON and OFF. Turned ON when i n use switch (positioned up). Usually turned OFF (positioned down). FCV (magnet valve) ON / OFF Turns the FC V (magnet valve) ON and OFF. Turned ON when i n use switch (positioned up). Usually turned OFF (positioned down). FCV (magnet valve) ON / OFF Turns the FC V (magnet valve) ON and OFF. Turned ON when i n use switch (positioned up). Usually turned OFF (positioned down). 4D56 ECU pilot lamp 4M41 ECU pilot lamp WL ECU pilot lamp Orange lamp lights when 4D56 ECU in use. Orange lamp lights when 4M41 ECU in use. Orange lamp lights when WL ECU in use. Orange lamp lights when ECU in use (when breaker is turned ON).
- 72 -
ADJUSTMENT
Key no
Name Turn to align with ECU in use. 0: All OFF 1: No. 1 ECU 2: No. 2 ECU 3: No. 3 ECU 4: Spare ECU
Power sub-switch for controller unit for VRZ adjustment. Press once to turn ON. When turned ON for use, orange lamp lights. Press once again to turn OFF. Green lamp lights when ROM in use.
ROM wire harness connecting For connecting injection pump's ROM harness connector to ROM controller terminal using wire harness.
CAUTION
If you smell any unusual smell or see smoke or sparks when using the controller unit, turn the power switch OFF immediately and stop using the controller unit. Fire may result if you continue to use the controller unit. Advice Do not use the controller unit with oily hands. The oil may stick to the dials and cause improper resistor contact inside the controller unit, preventing proper operation. Before turning the power switch ON, confirm that the wire harnesses are properly connected.
- 73 -
CE
P-VRZR- 345
Key no 1 2 3 4
Name AC100V - 120V power or AC 200V - 240V power terminal Main switch (breaker) D-sub 9 pin cable connection (COM1) D-sub 25 pin cable connection (COM2)
Use and purpose Connect to AC100V - 120V, 50/60Hz power source or AC 200V - 240V power source, 50/60Hz. Controller unit power switch. Turn ON when in use (position at 'I'). Position at 'O' to turn OFF. Connects RS232C cable to personal computer (for GE). Connects RS232C cable to personal computer (for Q-ROM)
CAUTION
If you smell any unusual smell or see smoke or sparks when using the controller unit, turn the power OFF immediately and stop using the controller unit. Fire may result if you continue to use the controller unit. Advice Do not use the controller unit with oily hands. The oil may stick to the dials and cause improper resistor contact inside the controller unit, preventing proper operation. Before turning the power switch ON, confirm that the wire harnesses are properly connected.
- 74 -
1. Password input Disagreement Agreement 2. ECU selection [1] 4D56 [2] 4M41 [3] WL [4] Manual operation [5] Workshop name registration [6] Exit [1] or [2] or [3] Part no. input [1] Adjustment [2] Inspection [4] Manual operation [5] Workshop name registration [6] Exit
Pre-check 1.
Input item [1] Workshop name [2] Address [3] Telephone [4] Fax [5] Operator's name [6] Password Inspection Step 1-XX Inspection Select "Registration" button
Confirmation
- 75 P-VRZR- 396
Program completed
Adjustment Step 1-XX Adjustment StepXX + 1 ROM compensation StepXX + 2 ROM writing Repeat measurement Adjustment result
Confirmation Repeat measurement Inspection result OK OK Push [MENU] button (= Registration change completed) Cancel Push [MENU] button (= Item is not changed)
ADJUSTMENT
Cancel
Print result
Cancel
Final confirmation
MC-02 TESTER
Copyright(C) 2001-2003 by Bosch Automotive Systems Corporation
RBAJ
1 2 3
ROM COVEC-F MITSUBISHI 12V Inspection/adjustment VRZ MITSUBISHI 12V Inspection/adjustment ROM COVEC-F MAZDA 12V Inspection/adjustment
4 5 6
Manual operation
Exit
P-VRZR- 346
No. 1 2 3 4 5 6
Name
4D56 model engine's COVEC-F type Select for inspection / adjustment of COVEC-F injection pump for injection pump inspection / adjustment key Mitsubishi 4D56 model engine 4M41 model engine's VRZ type injection pump inspection / adjustment key Select for inspection / adjustment of VRZ injection pump for Mitsubishi 4M41 model engine
WL model engine's COVEC-F type Select for inspection / adjustment of COVEC-F injection pump for injection pump inspection / adjustment key Mazda WL model engine Manual operation key Workshop registration key Exit key For adjusting injection pump and engine's installation timing For workshop registration To exit adjustment software
- 76 -
ADJUSTMENT 5. PUMP ADJUSTMENT TOOL MONITOR SCREEN OUTLINE Inspection and adjustment step screen
Pump adjustment tools for service
Input part no.
1 2 3 4 5 6 7 8 9 Only items necessary for each step are displayed. Circled numbers indicate fields where input is necessary. Back Next 10 11 23 12 13 18 14 15
19 20 21
MELCO
Adjustment VRZ(12V)
2001-01-15 11:28:44
V V V mm 0.0 mm3/st
MENU
22 17 16
24
Zero set Soll-cor Step information Step status
Comment
No.
STEP
N 1000rpm
Soll 2.91v
Soll-cor 0.00mv
TCVF 60Hz
DTCV 100%
03 P_cham_ADJ
PT standard point
Next
Sequence Select 03 / 32 After values are input, push 'Next' button. 500rpm 2.50v 60Hz 0%
25
P-VRZR- 347
04
No. 1 2 3 4 5 6 7 8 9 10 12 13 Pump speed input Test oil temperature input Actual control sleeve position voltage display Pump injection quantity input Pump chamber pressure input Pump overflow quantity input TF output display VTPS output display TPS output display TA output display Zero setting key Target control sleeve position compensation voltage key
Name N: pump speed T: test oil temperature U soll: actual control sleeve position voltage Q: pump injection quantity Pt: pump chamber pressure Qo: pump overflow quantity TF: fuel temperature VTPS: voltage at 0 mm timer stroke TPS: timer piston sensor output voltage TA: timer stroke DQ: variation between cylinders Input the pump's speed.
Use and purpose Input the test oil temperature. Displays actual control sleeve position voltage. Input pump's injection quantity. Input pump's chamber pressure. Input pump's overflow quantity. Displays fuel temperature output voltage. Displays VTPS output voltage (voltage at 0 mm timer stroke). Displays TPS (timer piston sensor) output voltage. Displays TA (timer stroke) output. Input pump's variation between injection quantities. TPS output voltage at TA = 0 mm can be set at 0 V. Any control sleeve position can be set by setting the compensation voltage. To set at next step. To set at any step ( To set at MENU display. To set at part number input display. Displays step status. Changes from red to green when all items are within specifications. Displays pump information part number (specification, pump) and serial number (pump, GE). Displays pump information specifications. Displays pump information measurement mode (inspection, adjustment). Displays date and time of measurements. Displays step status. Green: within specifications; red: outside of specifications. Displays current step items. Displays next step's items. BACK, NEXT).
14 NEXT key 15 Keys for moving to next or previous step 16 Menu key 17 Part number input key 18 Step status display 19 Part number, serial number display 20 Specification display
21 Measurement mode display 22 23 24 25 Measurement date display Status display Current step display Next step display
- 77 -
Manual operation
ECU reader data Item Value Unit Item Value Unit
GE Vist
Item Value
V
Unit
TPS Vist
Item Value
V
Unit
TF
Select ECU
deg C
Np
r/min
5 2
V mV % Hz
1. Values must be input for GE soll, TCV Duty and TCV Frequency. 2. Np values do not appear at VRZ pump adjustment.
3 4
Menu
Initialize ECU
P-VRZR- 348
No. 1 2 3 4 5
Name Control sleeve position actual voltage display Control sleeve position target voltage display Initialize ECU MENU Select ECU
Remarks Displays actual control sleeve position voltage. By operating the input keys, the control sleeve position can be set for the engine specified in No. 5. Clear display values Displays MENU screen. Select the ECU for the engine.
- 78 -
MC-02 TESTER
1 2 3 4 5 6
Menu
Registration
8
P-VRZR- 350
No. 1 2 3 4 5 6 7 8 Workshop name Address T elephone Fax Operator's name Password MENU Registration
Name Input comany name. Input company address. Input telephone number. Input fax number. Input operator's name.
Remarks
Input password and change password. Can be used to set MENU display. For keeping registered items.
MC-02 TESTER
Copyright(C) 2001-2003 by Bosch Automotive Systems Corporation
RBAJ
ROM COVEC-F MITSUBISHI 12V Inspection/adjustment VRZ MITSUBISHI 12V Inspection/adjustment ROM COVEC-F MAZDA 12V Inspection/adjustment
Manual operation
(1)
Workshop name registration Exit
P-VRZR- 346
MC-02 TESTER
(2)
(2) Input the company name, etc, in the fields on the screen. (3) Click the Registration button. Note: The default password at setup is RBAJ. Input a new password if desired. (The only limit to the number of figures and letters in the password is the size of the input field.)
(3)
Menu Registration
P-VRZR- 350
- 79 -
Preparation
See page 81 [2], 82 [3] See page 83 [4] See page 84 [5]
Part no. input and installation confirmation Warming-up operation Pre-stroke adjustment
See page 64 (9) See page 85 [6] See page 86 [7] See page 86 [8] See page 87 [9]
See page 88 [10] See page 88 [11] See page 89 [12] See page 89 [13]
Injection quantity compensation point adjustment Compensation ROM interpolation calculation Writing to the compensation ROM
- 80 -
P-VRZR- 351
(2) Read and record the 13 digit GE actuators serial number. Advice It is easier to read the GE actuators serial number before beginning Preparation. Note: Serial number input is used during adjustment mode and inspection mode.
GE serial number GE serial number
P-VRZR- 352
[2] Preparation
(1) Connect the test oil hose to the injection pump. (Refer to page 69 for the fuel piping.) (2) Connect the injection system piping to the injection pump. (Refer to page 68 for the injection system piping.) (3) Connect the controller assemblys wire harness and intermediate harness to the injection pumps connectors. (Refer to page 70 for the controller assemblys wiring.) (4) Connect the ROM controllers wire harness and intermediate harness to the injection pumps VRZ EEPROM connector. (5) Connect the FCV GND harness to the controller assemblys wire harness and to earth. (6) Connect the D-Sub 9 pin cable connector (COM 1) on the rear of the controller unit to the personal computer using the wire harness. (7) Connect the D-Sub 25 pin cable connector (COM 2) on the rear of the controller unit to the personal computer using the wire harness.
P-VRZR- 353
P-VRZR- 354
- 81 -
ADJUSTMENT
Fixing stand
(8) Reconfirm that the coupling and the fixing stand bolts and nuts are securely tightened. (9) Set the 20NP pump test benchs test oil outlet temperature at 45C. (10) Set the cooling unit oil delivery pressure lever at 80 kPa {0.8 kgf/cm2} or less.
P-VRZR- 355
ECU for VRZ type injection pump No. 1 ~ No. 4 changeover switch
P-VRZR- 397
(11) Connect the wire harness to the controller units No 2 ECU connector. (12) Turn the main switch on the rear of the controller unit ON. (13) Set the No 1 ~ No 4 changeover switch at No 2. (14) Turn the FCV (magnet valve) ON/OFF switch ON to energize the magnet valve. (15) Turn the sub switch on the front of the controller unit ON.
MC-02 TESTER
Precaution Password is required to actuate adjustment tools. Input password and press ENTER key.
(2) Start the Service tools for pump adjustment software. (3) Input the password and press the Enter key. Advice Input the initial default password RBAJ or your own password.
(3)
P-VRZR- 357
- 82 -
input
and
MC-02 TESTER
Copyright(C) 2001-2003 by Bosch Automotive Systems Corporation
RBAJ
ROM COVEC-F MITSUBISHI 12V Inspection/adjustment VRZ MITSUBISHI 12V Inspection/adjustment ROM COVEC-F MAZDA 12V Inspection/adjustment
Manual operation
Exit
P-VRZR- 346
MC-02 TESTER
If number input is correct, select Next button. If you need to input a different number, select Clear button.
(2) (3)
446613 443062
0880052496 5062008852056
(4) (5)
System specifications
Engine model Rotation Pump cylinders ECU
1. Specified part no. Pump Pump Specified part no. OEM type part no. Adjustment Inspection 003040 008040 104700-304* 003051 008051 104700-305* COVEC-F 104700-306* MITSUBISHI 003060 008060 109144-305* VRZ 44-6613 44-8813 109144-306* 104700-055* COVEC-F MAZDA 000550 008550 2. Pump part no. Example: Input pump part no. Full pump no. 443052 109144-3052 000551 104700-0551
Mode
Adjustment
Menu
Clear
Next
(6)
(2) When the dialog shown at left appears, input the specified part number (6 digits) and press Enter. (3) Input the pump part number (last 6 digits) and press Enter. (4) Input the pump serial number (10 digits) and press Enter. (5) Input the GEs serial number (13 digits) and press Enter. (6) Press the Next key.
P-VRZR- 358
MC-02 TESTER
Setup confirmation
Installation confirmation Click on appropriate item and explanatory illustration is displayed. 1. Injection system piping 2. Overflow piping 3. Adjustment controller wiring 4. Operation sequence
3 2 4 Key no. 1 2 3 4 Part name Part no. Note 157808-4720 Injection pipe Nozzle & nozzle holder assembly 1 688 901 035 Same as VP44 Joint Injection tube
(7) Confirm that the screen changes to the injection system piping display. Note: Clicking the different buttons (1. Injection system piping, 2. Overflow piping, 3. Adjustment controller wiring, and 4. Operation sequence) displays different Setup confirmation screens.
P-VRZR- 359
- 83 -
Status
Item
44-6613 44-3062 0880052496 50620-088-52056 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)
(4)
T Ua-ist Q
GE serial no. Engine model Rotation Pump cylinders ECU Mode Pump type
05/04/03 13:20:52
Menu Part number input Frequency 60Hz Duty 100%
Step information
(5) (6)
Step name
N 300r/min
Soll 2.80v
Soll-cor 0.00mv
Sequence Select
Warm-up
(2)
P-VRZR- 360
(1) Set the pump test bench delivery pressure at the specified 40 kPa {0.4 kgf/cm2}. (2) Confirm that the sequence is 01/31. (3) Run the injection pump at the specified speed N (see figure at left). (4) Measure N, T and Q on the pump test bench and input the values. Note: U ist is displayed automatically. (5) Confirm that the Step status field is green. (6) Proceed to the next step. Advice If U ist values are not as specified, press the Next button several times. Then, return to Step 01/31 using the back arrow. Repeat the Step 01/31 and confirm that U ist values are as specified. Note: If not as specified after confirming U ist several times, the GE may be faulty.
Status
Item
Unit
Specification
Tolerance
Pump information
Specified part no.
44-6613 44-3062 0880052496 50620-088-52056 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)
(9)
T Ua-ist Q
GE serial no. Engine model Rotation Pump cylinders ECU Mode Pump type
05/04/03 13:21:45
Menu Part number input Frequency 60Hz Duty 100%
Step information
Step name
N 1000r/min
Soll 2.91v
Soll-cor 0.00mv
(13) (14)
Sequence Select
P-cham_ADJ
(7) Confirm that the sequence is 02/31. (8) Run the injection pump at the specified speed N (see figure at left). (9) Measure N, T and Q on the pump test bench and input the values. Note: U ist is displayed automatically. (10) Confirm injection. (11) Confirm that no fuel leaks from the injection pump fuel piping connections.
(7)
P-VRZR- 361
CAUTION
If there are any fuel leaks, if there is no injection or if any unusual noises occur during operation, stop test bench operation immediately and inspect the pump. (12) Confirm that the injection pump is operating normally. (13) Confirm that the Step status field is green. (14) Proceed to the next step. Advice Because the test oil temperature takes longer to increase in cold weather, turn the pump test bench on earlier.
- 84 -
Status
Item
Unit
Specification
Tolerance
Pump information
Specified part no.
N T
44-6613 44-3062 0880052496 50620-088-52056 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)
Pump part no. Pump serial no. GE serial no. Engine model
(3)
Ua-ist Pt Qo TF
05/04/03 13:22:24
Menu Part number input Frequency 60Hz Duty 100%
Step information
(7) (8)
N 1000r/min
Soll 2.91v
Soll-cor 0.00mv
PT standard point 03 / 31 04
Sequence Select
Rough-Q_ADJ
(1)
P-VRZR- 362
(1) Confirm that the sequence is 03/31. (2) Run the injection pump at the specified speed N (see figure at left). (3) Measure N, T, Pt and Qo on the pump test bench and input the values. Note: U ist and Tf are displayed automatically. (4) If Pt is as specified, perform steps (7) and (8). If Pt is not as specified, adjust as described below. When the pump chamber pressure exceeds the specifications Replace the regulating valve assembly and adjust the pump chamber pressure to the specified pressure.
Holder Plug
Spring
When the pump chamber pressure is less than the specifications Attach the adjusting device to the regulating valve. Gradually press the regulating valve plug into the regulating valve assembly using the adjusting device to adjust the pump chamber pressure. Advice Do not press the plug in too far.
Tool name Adjusting device Part no 157829-0820 Remarks
P-VRZR- 240
(5) Measure N, T, Pt and Qo again on the pump test bench and input the values. (6) Confirm that the injection pump is operating normally. (7) Confirm that the Step status field is green. (8) Proceed to the next step. Advice If the overflow quantity is not as specified after confirming pump chamber pressure, check the overflow valve.
- 85 -
ADJUSTMENT
Service tools for pump adjustment Adjustment display
Status
Item
Unit
Specification
Tolerance
Pump information
Specified part no.
N T
44-6613 44-3062 0880052496 50620-088-52056 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)
Pump part no. Pump serial no. GE serial no. Engine model
(3)
Ua-ist Q DQ
05/04/03 13:23:05
Menu Part number input Frequency 60Hz Duty 100%
Step information
(9) (10)
N 1000r/min
Soll 2.91v
Soll-cor 0.00mv
Sequence Select
P-cham_ADJ
(1)
P-VRZR- 363
Injection quantity decrease (move GE actuator toward drive side) Move GE actuator to adjust
GE actuator
P-VRZR- 355
Status
Item
Unit
Specification
Tolerance
Pump information
Specified part no.
N T
44-6613 44-3062 0880052496 50620-088-52056 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)
Pump part no. Pump serial no. GE serial no. Engine model
[8] P u m p c h a m b e r confirmation
pressure
(3)
Ua-ist Pt Qo TF
05/04/03 13:23:42
Menu Part number input Frequency 60Hz Duty 100%
Step information
(5) (6)
N 1000r/min
Soll 2.91v
Soll-cor 0.00mv
Sequence Select
Zero_set
(1)
P-VRZR- 364
(1) Confirm that the sequence is 05/31. (2) Run the injection pump at the specified speed N (see figure at left). (3) Measure N, T, Pt and Qo on the pump test bench and input the values. Note: U ist and TF are displayed automatically. (4) Confirm the pump chamber pressure. (5) Confirm that the Step status field is green. (6) Proceed to the next step. Advice Recheck the feed pump.
- 86 -
ADJUSTMENT
Service tools for pump adjustment Adjustment display
Status
Item
Unit
Specification
Tolerance
(3)
44-6613 44-3062 0880052496 50620-088-52056 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)
Pump part no. Pump serial no. GE serial no. Engine model Rotation Pump cylinders ECU Mode Pump type
Timer_TA
(1)
P-VRZR- 365
(1) Confirm that the sequence is 06/31. (2) Run the injection pump at the specified speed N (see figure at left). (3) Measure N and T on the pump test bench and input the values. Note: U ist, VTPS and TPS are displayed automatically. (4) Press the Zero set key and confirm that the VTPS value is within the specifications. Note: VTPS is the voltage value for when the timer piston is 0 mm. (5) If the TPS is as specified, perform steps (7) and (8). If the TPS is not as specified, replace the TPS standard point shim to adjust the TPS initial output. TPS standard point shims
Shim part no
Th/ness (mm)
Shim part no 149653-0500 (9 443 613 475) 149653-0600 (9 443 612 842) 149653-0700 (9 443 613 476)
Th/ness (mm)
P-VRZR- 137
149653-0200 (9 443 613 473) 149653-0300 (9 443 612 841) 149653-0400 (9 443 613 474)
(6) Measure N and T again on the pump test bench and input the values. (7) Confirm that the Step status field is green. (8) Proceed to the next step.
- 87 -
Status
Item
Unit
Specification
Tolerance
Pump information
Specified part no.
44-6613 44-3062 0880052496 50620-088-52056 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)
(3)
T Ua-ist Pt VTPS TA
GE serial no. Engine model Rotation Pump cylinders ECU Mode Pump type
05/04/03 13:20:52
Menu Part number input Frequency 60Hz Duty 100%
Step information
(5) (6)
N 100r/min
Soll 2.41v
Soll-cor 0.00mv
100r/min 07 / 31 08
Sequence Select
Timer_TA
(1)
P-VRZR- 366
TPS
Spring
Pump housing
P-VRZR- 137
Status
Item
Unit
Specification
Tolerance
Pump information
Specified part no.
N T Ua-ist Pt VTPS TA
44-6613 44-3062 0880052496 50620-088-52056 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)
Pump part no. Pump serial no. GE serial no. Engine model Rotation Pump cylinders ECU Mode Pump type
Confirm 50 revolutions (Step 08/31) ~ 1,900 revolutions (Step 16/31) using the same procedure used for 100 revolutions (Step 7/31) above. Advice Repeat Step 06/31 if the timer stroke is not as specified.
05/04/03 13:25:27
Menu Part number input Frequency 60Hz Duty 100%
No. 08
N 50r/min
Soll 2.41v
Soll-cor 0.00mv
50r/min 08 / 31 09
Timer_TA
P-VRZR- 367
Status
Item
N T
44-6613 44-3062 0880052496 50620-088-52056 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)
Pump part no. Pump serial no. GE serial no. Engine model
(3)
Ua-ist Q DQ
05/04/03 13:35:08
Menu Part number input Frequency 60Hz Duty 100%
Step information
(4) (5)
N 2300r/min
Soll 0.87v
Soll-cor 0.00mv
Sequence Select
Cor-Q_ADJ
(1) Confirm that the sequence is 17/31. (2) Run the injection pump at the specified speed N (see figure at left). (3) Measure N, T, Q and DQ on the pump test bench and input the values. Note: U ist is displayed automatically. (4) Confirm that the Step status field is green. (5) Proceed to the next step.
(1)
P-VRZR- 368
- 88 -
Status
Item
Unit
Specification
Tolerance
Pump information
Specified part no.
N T
44-6613 44-3062 0880052496 50620-088-52056 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)
Pump part no. Pump serial no. GE serial no. Engine model
(3)
Ua-ist Q DQ
Correction point 10
Cor-Q_ADJ
(1)
P-VRZR- 369
Status
Item
Unit
Specification
Tolerance
Pump information
Specified part no.
N T Ua-ist Q DQ
44-6613 44-3062 0880052496 50620-088-52056 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)
Pump part no. Pump serial no. GE serial no. Engine model Rotation Pump cylinders ECU Mode Pump type
Correction point 9
Cor-Q_ADJ
P-VRZR- 370
Status
Item
Unit
Specification
Tolerance
Pump information
Specified part no. Pump part no. Pump serial no. GE serial no. Engine model Rotation
44-6613 44-3062 0880052496 50620-088-52056 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)
05/04/03 13:43:00
Menu Part number input Frequency 60Hz Duty 0%
No. 28
N 0r/min
Soll 0.00v
Soll-cor 0.00mv
ROM_overwrite
P-VRZR- 371
- 89 -
Status
Item
44-6613 44-3062 0880052496 50620-088-52056 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)
05/04/03 13:43:34
Menu Part number input Frequency 60Hz Duty 0%
No. 29
N 0r/min
Soll 0.00v
Soll-cor 0.00mv
Overwrite Q-ROM. 29 / 31 30
Stop_Q
(1) Press Step 28/31 to automatically display the step. (2) The adjustment software automatically writes the compensation Q data to the injection pumps Q adjustment ROM. Advice Never touch the computer, the injection pump or the connecting wire harnesses while writing to the ROM.
(1)
P-VRZR- 372
Status
Item
Unit
Specification
Tolerance
Pump information
Specified part no.
N T
44-6613 44-3062 0880052496 50620-088-52056 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)
Pump part no. Pump serial no. GE serial no. Engine model
[15] M a g n e t v a l v e o p e r a t i o n confirmation
(1) Confirm that the sequence is 30/31. (2) Run the injection pump at the specified speed N (see figure at left). (3) Measure N, T and Q on the pump test bench and input the values. Note: U ist is displayed automatically.
(3)
Ua-ist Q
05/04/03 13:44:15
Menu Part number input Frequency 60Hz Duty 100%
No. 30 Stop_Q
Step name
N 1000r/min
Soll 2.91v
Soll-cor 0.00mv
Q_characteristics
(1)
P-VRZR- 373
(4) Turn the FCV (magnet valve) ON/OFF switch OFF and confirm that non-injection results. Advice To confirm non-injection from the nozzle, look at the monitor screen and confirm that non-injection occurs within a short time (6 ~ 7 seconds).
P-VRZR- 356
Status
Item
Unit
Specification
Tolerance
Pump information
Specified part no.
N T
44-6613 44-3062 0880052496 50620-088-52056 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)
Pump part no. Pump serial no. GE serial no. Engine model
(5)
Ua-ist Q
(5) Measure N, T and Q again on the pump test bench and input the values. (6) Confirm that the Step status field is green. (7) Proceed to the next step.
05/04/03 13:44:15
Menu Part number input Frequency 60Hz Duty 100%
Step information
(6) (7)
Step name
N 1000r/min
Soll 2.91v
Soll-cor 0.00mv
Sequence Select
Q_characteristics
P-VRZR- 373
- 90 -
Note: The following describes the preparation for and performance of automatic adjustment of second timing. (1) Injection pump disassembly (1) Turn the sub-switch OFF.
P-VRZR- 356
Fuel piping
Injection pump
Coupling
(2) Disconnect the intermediate harness connectors. (3) Disconnect the fuel piping. (4) Remove the coupling. (5) Remove the pump from the fixing stand. (6) Remove the fixing stand.
O-ring
Nuts (3)
(2) Drive gear installation (1) Temporarily assemble the O-ring and bracket to the pump housing.
Bracket
P-VRZR- 252
(2) Assemble the drive shaft key in the drive shafts key groove.
Key
P-VRZR- 253
- 91 -
ADJUSTMENT
(3) Assemble the drive gear to the drive shaft.
Drive gear
P-VRZR- 254
(4) Assemble the drive gear fixing round nut to the drive shaft and tighten it lightly.
Round nut
P-VRZR- 255
Wrench
(5) Assemble the wrench to the drive gear and tighten the round nut (SW21) to the specified torque using a torque wrench. Specified torque: 167 ~ 185 Nm {17 ~ 18.7 kgfm}
Tool name Wrench Part no 157917-4620 Remarks
Torque wrench
P-VRZR- 256
- 92 -
ADJUSTMENT
(3) Injection pump installation (1) Attach the stand to the pump test bench.
Stand
Part no 105781-0890
Remarks
P-VRZR- 258
Stand
(2) Attach the injection pump to the stand. (3) Pull the stands handle as shown in the figure to fix the injection pump.
P-VRZR- 259
Pipe assembly
(4) Remove the CPV from cylinder B and attach the pipe assembly and the gasket.
Tool name Pipe assembly Part no 157845-9520 Remarks
P-VRZR- 260
Plugs
(5) Connect the test oil hose to the injection pump. (6) Attach the plugs to where the GE and the distributor head overflow valves were removed. Advice Install any suitable plugs to maintain pump chamber air tightness.
P-VRZR- 261
- 93 -
ADJUSTMENT
(7) Connect the controller assembly s main harness and intermediate harness to the injection pumps GE connector.
Tool name Main harness Intermediate harness Part no 157966-4920 157966-5720 Remarks
Main harness
Intermediate harness
P-VRZR- 262
Adjusting device
Chamfered tooth
(8) Align the adjusting devices pin hole with the injection pump brackets pin. In this position, attach the adjusting device to the injection pumps bracket and fix using the bolts.
Rack
Part no 105793-0020
Remarks
P-VRZR- 263
Sub-switch
Advice When aligning the adjusting devices pin hole with the brackets pin, position the adjusting devices rack teeth on either side of the drive gear s chamfered tooth. (4) Second timing adjustment (1) Turn the controller units sub-switch ON. (2) Supply test oil to the injection pump at the specified pressure of 20 kPa {0.2 kgf/cm2}.
P-VRZR- 356
Status
Item
Unit
Specification
Tolerance
Pump information
Specified part no.
N T Ua-ist Q DQ
44-6613 44-3062 0880052496 50620-088-52056 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)
Pump part no. Pump serial no. GE serial no. Engine model Rotation Pump cylinders ECU Mode
0.0 mm3/st
Pump type
05/04/03 13:44:46
Menu Part number input Frequency 60Hz Duty 100%
No. 31
N 0r/min
Soll 2.91v
Soll-cor 0.00mv
Second timing 31 / 31 _
Adjustment finished
(3)
P-VRZR- 376
- 94 -
ADJUSTMENT
Nuts (3)
P-VRZR- 264
(5) Loosen the bolt preventing drive shaft rotation and remove the FBB plate.
P-VRZR- 265
Pipe assembly
Adjusting device
(6) Insert the lever into the adjusting device and turn the lever once in the reverse rotation direction, then turn the lever in the direction of rotation. (7) Adjust so that test oil flows from cylinder Bs pipe assembly at a rate of 1 drop / 3 seconds.
P-VRZR- 266
(8) Tighten the bolt preventing drive shaft rotation to fix the drive shaft. Specified torque: 27 ~ 35 Nm {2.8 ~ 3.6 kgfm}
P-VRZR- 267
- 95 -
ADJUSTMENT
Nuts (3)
(9) Tighten the bracket nuts. Specified torque: 34 ~ 39 Nm {3.5 ~ 4.0 kgfm}
P-VRZR- 268
Timing mark
(10) Mark the timing mark on the injection pump and the bracket. Advice Erase the previous mark.
P-VRZR- 269
FBB plate
(11) Loosen the bolt preventing drive shaft rotation, install the FBB plate and fix the FBB plate by tightening the bolt preventing drive shaft rotation. Specified torque: 10 ~ 15 Nm {1.0 ~ 1.5 kgfm} (12) Turn the test oil switch OFF.
P-VRZR- 270
Status
Item
Unit
Specification
Tolerance
Pump information
Specified part no.
44-6613 44-3062 0880052496 50620-088-52056 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)
(13)
T Ua-ist Q DQ
GE serial no. Engine model Rotation Pump cylinders ECU Mode Pump type
(13) Measure T on the pump test bench and input the value. Note: U ist is displayed automatically. (14) Confirm that the Step status field is green. (15) Proceed to the next step.
05/04/03 13:44:46
Menu Part number input Frequency 60Hz Duty 100%
Step information
(14) (15)
N 0r/min
Soll 2.91v
Soll-cor 0.00mv
Second timing 31 / 31 _
Sequence Select
Adjustment finished
P-VRZR- 376
- 96 -
ADJUSTMENT
(5) Printing the adjustment results and saving the test record (1) Click the Next key. (2) Do you want to print and save test record is displayed. (3) Click OK. Note: If you select Cancel, you cannot continue to the next step. Advice The printed test record can be given to the customer. The saved test record is a record of all the data and must be handled carefully. (4) Turn the controller units sub-switch OFF. (5) Turn the controller units main switch OFF.
MC-02 TESTER
Adjustment result
Specified part no. Pump part no.
44-6613 44-3062
Step name N r/min
0880052496 50620-088-52056
N r/min T DegC Uaist V
Test complete
Adjustment necessary
No. Result
DTCV %
VTPS V
TA mm
TPS V
TF V
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Warm-up Warm-up P-cham_ADJ Rough-Q_ADJ P-cham_ADJ Zero_set Timer_TA Timer_TA Timer_TA Timer_TA Timer_TA Timer_TA Timer_TA Timer_TA Timer_TA Timer_TA Q_characteristics Cor-Q_ADJ Cor-Q_ADJ Cor-Q_ADJ Cor-Q_ADJ Cor-Q_ADJ Cor-Q_ADJ Cor-Q_ADJ Cor-Q_ADJ Cor-Q_ADJ Cor-Q_ADJ Cor-Q_ADJ
300 1000 1000 1000 1000 500 100 50 325 375 375 500 1000 1000 1900 1900 2300 1900 1900 1000 1000 600 600 600 600 375 325 100
2.80 2.91 2.91 2.91 2.91 2.50 2.41 2.41 1.53 1.53 1.53 1.53 2.91 2.91 3.73 3.73 0.87 2.91 3.73 1.53 2.91 1.53 2.20 1.86 1.53 1.86 1.86 2.41
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60
0.00 100 0 0.0 0.0 0.00 100 0 0.0 0.0 0.00 100 0 0.0 0.00 100 0 0.0 0.0 0.00 100 0 0.0 0.00 0 0 0.0 0.00 100 0 0.0 0.00 100 0 0.0 0.00 0 0 0.0 0.00 0 0 0.0 0.00 100 0 0.0 0.00 100 0 0.0 Do you want and save test record? 0.00 100 0 to print 0.0 0.00 100 0 0.0 0.0 100 OK 0 0.0 0.0 Cancel 0.00 0.00 100 0 0.0 0.0 0.00 100 0 0.0 0.0 0.00 100 0 0.0 0.0 0.00 100 0 0.0 0.0 0.00 100 0 0.0 0.0 0.00 100 0 0.0 0.0 0.00 100 0 0.0 0.0 0.00 100 0 0.0 0.0 0.00 100 0 0.0 0.0 0.00 100 0 0.0 0.0 0.00 100 0 0.0 0.0 0.00 100 0 0.0 0.0 0.00 100 0 0.0 0.0
0.000 0.0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
0.0 0.0 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00
If no further measurements are required, select Next button. To repeat a measurement, select Repeat button and input step number. Step number Repeat
Next
(1)
P-VRZR- 377
Adjusting device
(6) Injection pump removal (1) Remove the adjusting device from the injection pumps drive gear.
P-VRZR- 271
CPV
(2) Replace cylinder Bs pipe assembly with the CPV. At this time, replace the gasket with a new one.
Pipe assembly
P-VRZR- 272
- 97 -
ADJUSTMENT
Main harness Plug
(3) Disconnect the main harness and the intermediate harness from the injection pump. (4) Remove the test oil hose and the overflow valve plugs from the injection pump.
(5) Install the Q adjustment ROM to the pump housing. Note: Removing the inlet adapter facilitates installation. (6) Tighten the Q adjustment ROMs torx bolts. Specified torque: 2 ~ 3 Nm {0.2 ~ 0.3 kgfm}
Pump housing
Remarks
P-VRZR- 393
(7) Connect the overflow valves bypass hose to the injection pump. (8) Tighten the overflow valves using a torque wrench. Specified torque: 20 ~ 29 Nm {2 ~ 3 kgfm}
Overflow valve
P-VRZR- 274
P-VRZR- 275
- 98 -
ADJUSTMENT
(10) Remove the stand from the pump test bench.
Stand
P-VRZR- 276
(1) Turn the controller units sub-switch ON. (2) Supply test oil to the injection pump at the specified pressure of 20 kPa {0.2 kgf/cm2}.
P-VRZR- 397
MC-02 TESTER
Copyright(C) 2001-2003 by Bosch Automotive Systems Corporation
RBAJ
ROM COVEC-F MITSUBISHI 12V Inspection/adjustment VRZ MITSUBISHI 12V Inspection/adjustment ROM COVEC-F MAZDA 12V Inspection/adjustment
(3)
Manual operation
Exit
P-VRZR- 346
- 99 -
ADJUSTMENT
(4) Select the ECU (a black point appears when the ECU is selected). (5) Press Initialize ECU after selecting the ECU. (6) Press the GE soll button and input 2.91 into the field. Press the keyboards Enter key. (7) Press the TCV Duty button and input 100 into the field. Press the keyboards Enter key. (8) Press the TCV Frequency button and input 60 into the field. Press the keyboards Enter key. Advice Values must be input for GE soll, TCV Duty and TCV Frequency. (9) Loosen the injection pump bracket installation nuts.
MC-02 TESTER
Manual operation
ECU reader data Item Value Unit Item Value Unit
GE Vist
Item Value
V
Unit
TPS Vist
Item Value
V
Unit
TF
deg C
Np
r/min
Select ECU
ROM COVEC-F MITSUBISHI 12V VRZ MITSUBISHI 12V ROM COVEC-F MAZDA 12V
V mV % Hz
1. Values must be input for GE soll, TCV Duty and TCV Frequency. 2. Np values do not appear at VRZ pump adjustment.
Menu
P-VRZR- 348
Nuts (3)
P-VRZR- 264
(10) Loosen the bolt preventing drive shaft rotation and remove the FBB plate.
P-VRZR- 265
Pipe assembly
Adjusting device
(11) Insert the lever into the adjusting device and turn the lever once in the reverse rotation direction, then turn the lever in the direction of rotation. (12) Adjust so that test oil flows from cylinder Bs pipe assembly at a rate of 1 drop /3 seconds.
P-VRZR- 266
- 100 -
ADJUSTMENT
(13) Tighten the bolt preventing drive shaft rotation to fix the drive shaft. Specified torque: 27 ~ 35 Nm {2.8 ~ 3.6 kgfm}
P-VRZR- 267
Nuts (3)
(14) Tighten the bracket nuts. Specified torque: 34 ~ 39 Nm {3.5 ~ 4.0 kgfm}
P-VRZR- 268
Timing mark
(15) Mark the timing mark on the injection pump and the bracket. Advice Erase the previous mark.
P-VRZR- 269
FBB plate
(16) Loosen the bolt preventing drive shaft rotation, install the FBB plate and fix the FBB plate by tightening the bolt preventing drive shaft rotation. Specified torque: 10 ~ 15 Nm {1.0 ~ 1.5 kgfm} (17) Turn the test oil switch OFF. (18) Remove the injection pump as described in (6) Injection pump removal [steps (1) to (10)] on pages 97 to 99.
P-VRZR- 270
- 101 -
Preparation
See page 103 [2], 104 [3] See page 105 [4]
Warming-up operation
TPS confirmation
See page 107 [8] See page 108 [9] See page 108 [10]
Non-injection confirmation
- 102 -
P-VRZR- 351
(2) Read and record the 13 digit GE actuator serial number. Advice It is easier to read the GE actuators serial number before beginning Preparation. Note: Serial number input is used during adjustment mode and inspection mode.
GE serial number GE serial number
P-VRZR- 352
[2] Preparation
(1) Connect the test oil hose to the injection pump. (Refer to page 69 for the fuel piping.) (2) Connect the injection system piping to the injection pump. (Refer to page 68 for the injection system piping.) (3) Connect the controller assemblys wire harness and intermediate harness to the injection pumps connectors. (Refer to page 70 for the controller assemblys wiring.) (4) Connect the ROM controllers wire harness and intermediate harness to the injection pumps VRZ EEPROM connector. (5) Connect the FCV GND harness to the controller assemblys wire harness and to earth. (6) Connect the D-Sub 9 pin cable connector (COM 1) on the rear of the controller unit to the personal computer using the wire harness. (7) Connect the D-Sub 25 pin cable connector (COM 2) on the rear of the controller unit to the personal computer using the wire harness.
P-VRZR- 353
P-VRZR- 354
- 103 -
INSPECTION
Fixing stand
(8) Reconfirm that the coupling and the fixing stand bolts and nuts are securely tightened. (9) Set the 20NP pump testers test oil outlet temperature at 45C. (10) Set the cooling unit oil delivery pressure lever at 80 kPa {0.8 kgf/cm2} or less.
P-VRZR- 355
ECU for VRZ type injection pump No. 1 ~ No. 4 change-over switch
P-VRZR- 397
(11) Connect the wire harness to the controller units No 2 ECU connector. (12) Turn the main switch on the rear of the controller unit ON. (13) Set the No 1 ~ No 4 changeover switch at No 2. (14) Turn the FCV (magnet valve) ON/OFF switch ON to energize the magnet valve. (15) Turn the sub switch on the front of the controller unit ON.
[3] I n s p e c t i o n s o ft w a r e s e t u p : preparation
(1) Turn the computer and the monitor power switches ON.
MC-02 TESTER
Precaution Password is required to actuate adjustment tools. Input password and press ENTER key.
(2) Start the Service tools for pump adjustment software. (3) Input the password and press the Enter key. Advice Input the initial default password RBAJ or your own password.
(3)
P-VRZR- 357
- 104 -
input
and
MC-02 TESTER
Copyright(C) 2001-2003 by Bosch Automotive Systems Corporation
RBAJ
ROM COVEC-F MITSUBISHI 12V Inspection/adjustment VRZ MITSUBISHI 12V Inspection/adjustment ROM COVEC-F MAZDA 12V Inspection/adjustment
Manual operation
Exit
P-VRZR- 346
MC-02 TESTER
If number input is correct, select Next button. If you need to input a different number, select Clear button.
(2) (3)
446613 443062
5555555555 6666666666666
(4) (5)
System specifications
Engine model Rotation Pump cylinders ECU
1. Specified part no. Pump Pump Specified part no. OEM type part no. Adjustment Inspection 003040 008040 104700-304* 003051 008051 104700-305* COVEC-F 104700-306* MITSUBISHI 003060 008060 109144-305* VRZ 44-6613 44-8813 109144-306* 104700-055* COVEC-F MAZDA 000550 008550 2. Pump part no. Example: Input pump part no. Full pump no. 443052 109144-3052 000551 104700-0551
Mode
Inspection
Menu
Clear
Next
(6)
(2) When the dialog shown at left appears, input the specified part number (6 digits) and press Enter. (3) Input the pump part number (last 6 digits) and press Enter. (4) Input the pump serial number (10 digits) and press Enter. (5) Input the GEs serial number (13 digits) and press Enter. (6) Press the Next key.
P-VRZR- 378
MC-02 TESTER
Setup confirmation
Installation confirmation Click on appropriate item and explanatory illustration is displayed. 1. Injection system piping 2. Overflow piping 3. Adjustment controller wiring 4. Operation sequence
3 2 4 Key no. 1 2 3 4 Part name Part no. Note 157808-4720 Injection pipe Nozzle & nozzle holder assembly 1 688 901 035 Same as VP44 Joint Injection tube
(7) Confirm that the screen changes to the injection system piping display.
P-VRZR- 359
- 105 -
Status
Item
44-8813 44-3052 5555555555 66666-666-66666 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)
(4)
T Ua-ist Q
GE serial no. Engine model Rotation Pump cylinders ECU Mode Pump type
02/04/03 14:07:56
Menu Part number input Frequency 60Hz Duty 100%
Step information
Step name
N 300r/min
Soll 2.80v
Soll-cor 0.00mv
(5) (6)
Sequence Select
Warm-up
(2)
P-VRZR- 379
(1) Set the pump test bench delivery pressure at the specified 40 kPa {0.4 kgf/cm2}. (2) Confirm that the sequence is Step 01/26. (3) Run the injection pump at the specified speed N (see figure at left). (4) Measure N, T and Q on the pump test bench and input the values. Note: U ist is displayed automatically. (5) Confirm that the Step status field is green. (6) Proceed to the next step. Advice If U ist values are not as specified, press the Next button several times. Then, return to Step 01/26 using the back arrow. Repeat the Step 01/26 and confirm that U ist values are as specified. Note: If not as specified after confirming U ist several times, the GE may be faulty.
Status
Item
Unit
Specification
Tolerance
Pump information
Specified part no.
44-8813 44-3052 5555555555 66666-666-66666 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)
(9)
T Ua-ist Q
GE serial no. Engine model Rotation Pump cylinders ECU Mode Pump type
02/04/03 14:09:35
Menu Part number input Frequency 60Hz Duty 100%
Step information
Step name
N 1000r/min
Soll 2.91v
Soll-cor 0.00mv
(13) (14)
Sequence Select
P-cham_ADJ
(7) Confirm that the sequence is Step 02/26. (8) Run the injection pump at the specified speed N (see figure at left). (9) Measure N, T and Q on the pump test bench and input the values. Note: U ist is displayed automatically. (10) Confirm injection. (11) Confirm that no fuel leaks from the injection pump fuel piping connections.
(7)
P-VRZR- 380
CAUTION
If there are any fuel leaks, if there is no injection or if any unusual noises occur during operation, stop test bench operation immediately and inspect the pump. (12) Confirm that the injection pump is operating normally. (13) Confirm that the Step status field is green. (14) Proceed to the next step. Advice Because the test oil temperature takes longer to increase in cold weather, turn the pump test bench on earlier.
- 106 -
Status
Item
Unit
Specification
Tolerance
Pump information
Specified part no.
N T
44-8813 44-3052 5555555555 66666-666-66666 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)
Pump part no. Pump serial no. GE serial no. Engine model
(3)
Ua-ist Pt Qo TF
02/04/03 14:10:05
Menu Part number input Frequency 60Hz Duty 100%
Step information
(5) (6)
N 1000r/min
Soll 2.91v
Soll-cor 0.00mv
Sequence Select
Zero_set
(1)
P-VRZR- 386
(1) Confirm that the sequence is Step 03/26. (2) Run the injection pump at the specified speed N (see figure at left). (3) Measure N, T, Pt and Qo on the pump test bench and input the values. Note: U ist and Tf are displayed automatically. (4) Confirm the pump chamber pressure. (5) Confirm that the Step status field is green. (6) Proceed to the next step.
Status
Item
(3)
44-6613 44-3062 0880052496 50620-088-52056 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)
Pump part no. Pump serial no. GE serial no. Engine model Rotation Pump cylinders ECU Mode Pump type
(4)
Zero set Step information
No. Present step Comment 04 Zero_set Step name N 500r/min Soll 2.50v
05/04/03 14:10:51
Menu Soll-cor 0.00mv Part number input Frequency 60Hz Duty 0%
(5) (6)
Sequence Select
Timer_TA
(1)
P-VRZR- 387
(1) Confirm that the sequence is Step 04/26. (2) Run the injection pump at the specified speed N (see figure at left). (3) Measure N and T on the pump test bench and input the values. Note: U ist, VTPS and TPS are displayed automatically. (4) Press the Zero set key and confirm that the VTPS value is within the specifications. (5) Confirm that the Step status field is green. (6) Proceed to the next step.
Status
Item
Unit
Specification
Tolerance
Pump information
Specified part no.
44-6613 44-3062 0880052496 50620-088-52056 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)
(3)
T Ua-ist Pt VTPS TA
GE serial no. Engine model Rotation Pump cylinders ECU Mode Pump type
05/04/03 14:11:50
Menu Part number input Frequency 60Hz Duty 100%
Step information
(5) (6)
N 100r/min
Soll 2.41v
Soll-cor 0.00mv
100r/min 05 / 26 06
Sequence Select
Timer_TA
(1)
P-VRZR- 388
(1) Confirm that the sequence is Step 05/26. (2) Run the injection pump at the specified speed N (see figure at left). (3) Measure N, T and Pt on the pump test bench and input the values. Note: U i s t , V T P S a n d TA a r e d i s p l a y e d automatically. (4) Confirm that the timer stroke TA is within the specifications. (5) Confirm that the Step status field is green. (6) Proceed to the next step.
- 107 -
INSPECTION
Confirm 50 revolutions (Step 06/26) ~ 1,900 revolutions (Step 14/26) using the same procedure used for 100 revolutions (Step 5/26) above.
Status
Item
Unit
Specification
Tolerance
Pump information
Specified part no.
N T Ua-ist Pt VTPS TA
44-6613 44-3062 0880052496 50620-088-52056 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)
Pump part no. Pump serial no. GE serial no. Engine model Rotation Pump cylinders ECU Mode Pump type
05/04/03 14:11:50
Menu Part number input Frequency 60Hz Duty 100%
No. 05
N 100r/min
Soll 2.41v
Soll-cor 0.00mv
100r/min 05 / 26 06
Timer_TA
P-VRZR- 381
Status
Item
Unit
Specification
Tolerance
Pump information
Specified part no.
N T
44-8813 44-3052 5555555555 66666-666-66666 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)
Pump part no. Pump serial no. GE serial no. Engine model
(3)
Ua-ist Q DQ
0.0 mm3/st
Pump type
02/04/03 14:13:11
Menu Part number input Frequency 60Hz Duty 100%
Step information
(4) (5)
N 2300r/min
Soll 0.87v
Soll-cor 0.00mv
Sequence Select
Cor-Q_INSP
(1) Confirm that the sequence is Step 15/26. (2) Run the injection pump at the specified speed N (see figure at left). (3) Measure N, T, Q and DQ on the pump test bench and input the values. Note: U ist is displayed automatically. (4) Confirm that the Step status field is green. (5) Proceed to the next step.
(1)
P-VRZR- 382
Status
Item
N T
44-8813 44-3052 5555555555 66666-666-66666 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)
Pump part no. Pump serial no. GE serial no. Engine model
(3)
Ua-ist Q DQ
02/04/03 14:13:47
Menu Part number input Frequency 60Hz Duty 100%
Step information
(4) (5)
N 1000r/min
Soll 2.91v
Soll-cor -34.18mv
Correction point 8 16 / 26 17
Sequence Select
Cor-Q_INSP
(1)
P-VRZR- 383
(1) Confirm that the sequence is Step 16/26. (2) Run the injection pump at the specified speed N (see figure at left). (3) Measure N, T, Q and DQ on the pump test bench and input the values. Note: U ist is displayed automatically. Advice Do not perform injection quantity adjustment. (4) Confirm that the Step status field is green. (5) Proceed to the next step. Confirm compensation point 11 (Step 17/26) ~ compensation point 1 (Step 25/26) using the same procedure used for compensation point 10 (Step 16/26) above.
Status
Item
Unit
Specification
Tolerance
Pump information
Specified part no.
N T Ua-ist Q DQ
44-8813 44-3052 5555555555 66666-666-66666 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)
Pump part no. Pump serial no. GE serial no. Engine model Rotation Pump cylinders ECU Mode Pump type
02/04/03 14:13:47
Menu Part number input Frequency 60Hz Duty 100%
No. 16
N 1000r/min
Soll 2.91v
Soll-cor -34.18mv
Correction point 8 16 / 26 17
Cor-Q_INSP
P-VRZR- 383
- 108 -
INSPECTION
Service tools for pump adjustment Adjustment display
Status
Item
Unit
Specification
Tolerance
Pump information
Specified part no.
44-8813 44-3052 5555555555 66666-666-66666 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)
[11] M a g n e t v a l v e o p e r a t i o n confirmation
(1) Confirm that the sequence is Step 26/26. (2) Run the injection pump at the specified speed N (see figure at left). (3) Measure N, T and Q on the pump test bench and input the values. Note: U ist is displayed automatically.
(3)
T Ua-ist Q
GE serial no. Engine model Rotation Pump cylinders ECU Mode Pump type
02/04/03 14:14:59
Menu Part number input Frequency 60Hz Duty 100%
No. 26 Stop_Q
Step name
N 1000r/min
Soll 2.91v
Soll-cor 0.00mv
Inspection finished
(1)
P-VRZR- 384
(4) Turn the FCV (magnet valve) ON/OFF switch OFF and confirm that non-injection results. Advice To confirm non-injection from the nozzle, look at the monitor screen and confirm that non-injection occurs within a short time (6 ~ 7 seconds).
P-VRZR- 356
Status
Item
Unit
Specification
Tolerance
Pump information
Specified part no.
44-8813 44-3052 5555555555 66666-666-66666 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)
(5)
T Ua-ist Q
GE serial no. Engine model Rotation Pump cylinders ECU Mode Pump type
(5) Measure N, T and Q on the pump test bench and input the values. (6) Confirm that the Step status field is green. (7) Proceed to the next step.
02/04/03 14:14:59
Menu Part number input Frequency 60Hz Duty 100%
Step information
Step name
N 1000r/min
Soll 2.91v
Soll-cor 0.00mv
(6) (7)
Sequence Select
Inspection finished
P-VRZR- 384
- 109 -
MC-02 TESTER
44-8813 44-3052
Step name N r/min
5555555555 66666-666-66666
N r/min T DegC Uaist v
Test complete
Adjustment necessary
No. Result
DTCV %
VTPS v
TA mm
TPS V
TF V
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Warm-up Warm-up P-cham_ADJ Zero_set Timer_TA Timer_TA Timer_TA Timer_TA Timer_TA Timer_TA Timer_TA Timer_TA Timer_TA Timer_TA Q_characteristics Cor-Q_INSP Cor-Q_INSP Cor-Q_INSP Cor-Q_INSP Cor-Q_INSP Cor-Q_INSP Cor-Q_INSP Cor-Q_INSP Cor-Q_INSP Cor-Q_INSP Stop_Q
300 1000 1000 500 100 50 325 375 375 500 1000 1000 1900 1900 2300 1000 1900 2300 600 600 375 375 325 325 100 1000
2.80 0.00 2.91 0.00 2.91 0.00 2.50 0.00 2.41 0.00 2.41 0.00 1.53 0.00 1.53 0.00 1.53 0.00 1.53 0.00 2.91 0.00 2.91 0.00 3.73 0.00 3.73 0.00 0.87 0.00 2.91 -34.18 3.73 34.18 1.93 -14.65 2.20 58.59 1.86 -43.95 1.86 -63.48 1.53 -63.48 1.86 -53.71 1.53 -63.71 2.41 136.72 2.91 0.00
60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60
2.80 100 0 0.0 0.0 2.90 100 0 0.0 0.0 2.91 100 0 0.0 2.50 0 0 0.0 2.41 100 0 0.0 2.41 100 0 0.0 0.00 0 0 0.0 0.00 100 0 0.0 1.52 100 0 0.0 1.52 0 0 0.0 0.00 100 0 0.0 0.00 100 0 0.0 Do you want and save test record? 0.00 100 0 to print 0.0 0.00 100 0 0.0 0.0 100 OK 0 0.0 0.0 Cancel 0.00 0.00 100 0 0.0 0.0 3.76 100 0 0.0 0.0 1.91 100 0 0.0 0.0 2.26 100 0 0.0 0.0 2.26 100 0 0.0 0.0 0.00 100 0 0.0 0.0 0.00 100 0 0.0 0.0 0.00 100 0 0.0 0.0 0.00 100 0 0.0 0.0 2.54 100 0 0.0 0.0 2.90 100 0 0.0 0.0
0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
0.0 0.78 0.78 0.78 0.00 0.00 0.78 0.78 0.77 0.78 0.76 0.76 0.78 2.80 2.80 0.00 0.00 2.80 2.80 2.76 2.80 2.72 2.72
0.00
If no further measurements are required, select Next button. To repeat a measurement, select Repeat button and input step number. Step number Repeat
Next
(1)
P-VRZR- 385
(1) Click the Next key. (2) The message Do you want to print and save test record appears. (3) Click OK. Note: If you select Cancel, you cannot continue to the next step. Advice The printed test record can be given to the customer. The saved test record is a record of all the data and must be handled carefully. (4) Turn the controller units sub-switch OFF. (5) Turn the controller units main switch OFF.
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TIGHTENING TORQUES
Units: Nm {kgfm}
P-VRZR- 389
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(1): VRZ type injection pump (2): Number of cylinders 0 spare 1 spare 2 spare 3 3 cylinders 4 4 cylinders 5 5 cylinders 6 6 cylinders 7 spare 8 spare 9 master pump (3): Number of plungers - diameter 0 2 - 6.5 1 2 - 7 2 2 - 7.5 3 2 - 8 4 2 - 8.5 5 2 - 9 6 spare 7 spare 8 spare 9 spare (4): Engine manufacturer 0 Mazda 1 Isuzu 2 Nissan (Motor) 3 Mitsubishi (Motors) 4 Nissan (Diesel), Komatsu, others 5 spare 6 spare 7 spare 8 spare 9 spare (5): Proper number Design sequence starting from 00 with each change in the first seven digits. (6): Suffix
** E
(4) (5)
****
(6)
R NP * * *
(7) (8)
Manufactured by Bosch Automotive Systems Corporation VRZ type injection pump Number of cylinders Plunger diameter Electronic governor Maximum controlled governor speed (r/min) Direction of pump rotation R: clockwise viewed from drive side L: counter clockwise viewed from drive side (8): Proper number
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Pub. No: EE14E-11162 FUEL INJECTION PUMP MODEL VRZ Service Manual Repair Service & Maintenance Printing: September 2003 Published by: Bosch K.K. Sales Automotive Aftermarket Division
Printed in Japan C Copyright 2003, Bosch K.K. WPGVS-02