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Pub. No.

EE14E-11162

SERVICE MANUAL
VRZ

REPAIR SERVICE & MAINTENANCE

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

Publication number EE14E-11150 EC18E-11081 EC18E-11091 EC14E-11022 ED14E-11011 ED14E-11021

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

SERVICE PRECAUTIONS [1] Carrying the injection pump


Never knock or drop the injection pump when carrying it.

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

[2] Disassembly and reassembly


Only the mechanical components of the injection pump body can be disassembled and reassembled. Advice Do not disassemble the GE actuator other than directed in this manual. The GE actuator consists of electrical components. Do not damage them.
P-VRZR- 322

Injection pump

Harness connectors GE actuator

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.

Wire harness Injection pump

P-VRZR- 323

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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-

SPECIAL TOOLS [2] Disassembly, inspection and reassembly tool table


The following special tools (in addition to general tools such as spanners, hammer, etc) are required for VRZ type injection pump disassembly and reassembly.
Key no 1 2 3 4 5 6 7 8 9 10 11 RBAJ part no Bosch part no Part name Qty 1 1 1 1 2 1 1 1 1 1 1 Remarks Bracket (used together with key nos 2, 3, 4 and 5) For fixing VRZ pump For fixing bracket (key no 2) For fixing bracket (key no 2) For fixing brackets (key nos 3 and 4) For removing and installing regulating valve For removing and installing feed pump assembly For removing and installing CPV holder For protecting oil seal (shaft dia: 25) For removing oil seal (shaft dia: 25) For measuring rotor's axial play (tool for measuring VE cam lift) 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 157845-8900 9 681 610 626 Adapter 105782-4530 9 680 610 094 Measuring device 157917-4620 9 681 610 710 Wrench 157848-2300 9 681 611 027 Oil seal guide 157926-2421 9 681 610 773 Extractor 157927-4500 9 443 613 008 Puller 157928-5820 9 443 613 397 Hook 157928-3120 9 442 612 297 Clip 157928-3620 9 442 612 298 Holder 157928-4200 9 442 612 369 Guide 157928-4500 9 442 612 300 Set screw 157928-4700 9 442 612 301 Spacer 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Used together with key no 11 For measuring drive shaft play (shaft dia: 25) For preventing gear rotation on 4 cylinder pumps For installing pump housing oil seal For removing drive gear and coupling For removing drive gear For removing drive shaft snapring For installing drive shaft snapring For removing and installing bearing For centering feed pump cover For centering feed pump's threaded holes For positioning ball bearing For measuring pre-stroke For driving pump (shaft dia: 25) For SW6.35 bit For removing and installing feed pump (T15; used together with key no 26) 28 157915-9301 9 681 610 685 Bit 1 For removing and installing pre-stroke adjustment plate (T20; used together with key no 26) 29 157915-9600 9 681 611 015 Bit 1 For removing and installing outer screws (T30; used together with key no 26)

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

Remarks For removing and installing pump support bracket (T50)

157915-9700 9 681 610 686 Socket

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

1. 157944-8521 (9 681 610 317) Universal vise

2. 157945-2020 (9 681 610 812) Bracket

3. 157944-7100 (9 681 610 340) Bracket

4. 157944-7200 (9 681 610 797) Bracket

5. 010010-2220 (9 442 612 366) Bolt

6. 157913-7000 (0 986 612 682) Socket wrench

7. 157928-4320 (9 442 612 367) Feed pump holder

8. 157914-3600 (9 681 610 678) Socket wrench

9. 157928-4000 (9 442 612 368) Oil seal guide

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SPECIAL TOOLS

10. 157928-4120 (9 442 612 299) Extractor

11. 157829-3520 (9 681 610 171) Measuring device

12. 157845-8900 (9 681 610 626) Adapter

13. 105782-4530 (9 680 610 094) Measuring device

14. 157917-4620 (9 681 610 710) Wrench

15. 157848-2300 (9 681 611 027) Oil seal guide

46

25

75

16. 157926-2421 (9 681 610 773) Extractor

17. 157927-4500 (9 443 613 008) Puller

18. 157928-5820 (9 443 613 397) Hook

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SPECIAL TOOLS

19. 157928-3120 (9 442 612 297) Clip

20. 157928-3620 (9 442 612 298) Holder

21. 157928-4200 (9 442 612 369) Guide

22. 157928-4500 (9 442 612 300) Set screw

23. 157928-4700 (9 442 612 301) Spacer

24. 105782-4540 (9 680 610 095) Measuring device

25. 157847-0820 (9 442 612 370) Coupling

26. 157915-9820 (9 681 610 687) Holder

27. 157915-9201 (9 681 610 684) Bit

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SPECIAL TOOLS

28. 157915-9301 (9 681 610 685) Bit

29. 157915-9600 (9 681 611 015) Bit

30. 157915-9700 (9 681 610 686) Socket

31. 157928-4800 (9 442 612 302) Plate

32. 157917-4920 (9 681 610 711) Wrench

33. 157977-8000 (9 681 610 829) Adapter

34. 026512-1640 (9 421 617 041) Gasket

35. 157971-0500 (9 443 613 408) Clip

36. 157924-8520 (9 681 611 028) Base


172 138

37. 157928-4400 (9 442 612 371) Pliers

-8-

SPECIAL TOOLS 2. ADJUSTMENT TOOLS [1] Tool use locations

9 8

1 7

P-VRZR- 325

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SPECIAL TOOLS [2] Adjustment tool table


(1) Bosch Automotive System specifications
Key no 1 2 3 RBAJ part no 105796-0000 157808-4720 157641-6820 Bosch part no Part name Qty 1 4 1 Remarks For driving pump; center height: 125mm Inner dia 1.6 outer dia 6 - length 450mm The VP44 adjustment tool Bosch part no 0 986 611 876 (key no. 4 in the table below) can also be used instead of this tool. 4 5 6 7 8 9 157811-9020 157829-0820 157971-1020 105781-0890 105793-0020 157845-9520 9 681 610 453 Flange 9 681 610 336 Adjusting device 9 443 613 442 Piping assembly 9 680 610 087 Stand 9 681 610 418 Adjusting device 9 681 610 630 Pipe assembly 1 1 1 1 1 1 For fixing pump For adjusting regulating valve pressure Test oil overflow piping For fixing pump at injection timing adjustment For injection timing adjustment For pre-stroke and injection timing adjustment

1 688 010 129 Fixing stand 9 442 612 278 Injection pipe 9 443 612 974 Joint assembly

(2) Bosch specifications


Key no 1 Bosch part no Part name Qty 1 Three-way valve Remarks

1 687 010 126 VE pump overflow accessory set

1 688 901 035 Nozzle, nozzle holder assembly

Bosch type X... for VP44 test device, orifice 0.5 mm

1 687 010 130 Cooling unit

Includes injection tubing from nozzle assembly to cooling unit and from cooling unit to flow meter

0 986 611 876

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.

0 986 612 269

Adapter

Used together with above joint assembly.

Note: Center height is the height from the center of the pump test benchs flywheel to the drive stand.

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SPECIAL TOOLS

1. 105796-0000 (1 688 010 129) Fixing stand

2. 157808-4720 (9 442 612 278) Injection pipe

3. 157641-6820 (9 443 612 974) Joint assembly

4. 157811-9020 (9 681 610 453) Flange

5. 157829-0820 (9 681 610 336) Adjusting device

6. 157971-1020 (9 443 613 442) Piping assembly


200 M12X1.5

11

M10X1.0

7.

105781-0890 (9 680 610 087) Stand

8.

105793-0020 (9 681 610 418) Adjusting device

9 . 157845-9520 (9 681 610 630) Pipe assembly

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SPECIAL TOOLS [3] Adjustment controller assembly breakdown:


Key no. 1: 105782-8360 (9 680 610 209) Note: The numbers in brackets below are Bosch part numbers.
1:105782-8360 (9 680 610 209) 1-1: 157966-4020 (9 443 613 446) 1-1-1: 157966-4120 (9 443 613 447) 1-1-2: 157966-4420 (9 443 613 448) 1-1-3: 157966-4520 (9 443 613 449) 1-1-4: 157966-4620 (9 443 613 450) 1-1-5: 157966-4720 (9 443 613 451) 1-1-6: 157966-4820 (9 443 613 452) 1-1-7: 157966-4920 (9 443 613 453) 1-1-8: 157966-5020 (9 443 613 454) 1-1-9: 157966-5100 (9 443 613 455)

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

157966-4020 (9 443 613 446) CONTROLLER ASSY

1-1-1

157966-4120 (9 443 613 447) Controller unit

1-1-2

157966-4420 (9 443 613 448) Wire harness

1-1-3

157966-4520 (9 443 613 449) Wire harness

1-1-4

157966-4620 (9 443 613 450) Wire harness

1-1-5

157966-4720 (9 443 613 451) Wire harness

1-1-6

157966-4820 (9 443 613 452) Wire harness

2000

2000 1000

1-1-7

157966-4920 (9 443 613 453) Main harness

1-1-8

157966-5020 (9 443 613 454) Main harness

1-1-9

157966-5100 (9 443 613 455) CD-ROM

2000 2990

- 13 -

SPECIAL TOOLS

1-3

157966-3820 (9 443 613 457) ECU assembly (4M41)

[4] Intermediate harness table


Key no 1 2 RBAJ part no 157966-5720 157966-2421 Bosch part no Part name Qty 1 1 4M41 VRZ GE For 4M41, 4D56 ROM Remarks

9 443 613 460 Intermediate harness 9 443 613 462 Intermediate harness

1. 157966-5720
(9 443 613 460) Intermediate harness (4M41)

2.

157966-2421 (9 443 613 462) Intermediate harness (4M41, 4D56 ROM)

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

102 911 910

61

62

54

P-VRZR- 326

- 15 -

DISASSEMBLY
Injection pump body

3. ENGINE DRIVE GEAR REMOVAL


(1) Fix the injection pump bracket in a vise.

P-VRZR- 300

Bolt (M6x1)

Wrench A Drive gear

(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)

Wrench A Drive gear

(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

(9) Remove the roundnut (SW21) fixing the drive gear.


Socket wrench

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

Drive shaft Puller B

(11) Assemble puller B to the drive shaft and puller A.

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

(13) Remove the drive shaft key.


Key

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.

4. DISASSEMBLY [1] Injection pump installation


(1) Remove the overflow valves, the bypass hoses and the inlet pipe from the GE actuator and the distributor head and drain any fuel oil from the pump.

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 Position at front.

Bracket A Bracket B
Bracket B Bracket C
P-VRZR- 017

Bracket C Bolt

Injection pump

(4) Attach the injection pump to bracket C.

Bracket C

P-VRZR- 309

TCV harness connector

(5) Remove the bracket bolts. (6) Remove the TCV harness connector.

Bracket bolts
P-VRZR- 310

- 19 -

DISASSEMBLY
Grommet Magnet valve Nut

[2] Magnet valve removal


(1) Remove the magnet valve harness grommet and then remove the harness nut. (2) Remove the magnet valve and the filter. Advice Do not lose the armature spring.

P-VRZR- 020

Holder GE actuator

GE cover Torx bolts (6) Spring washers (6)

[3] GE actuator removal


(1) Remove the GE actuator s torx bolts and spring washers.
Tool name Part no 157915-9820 157915-9600 T30 Remarks

Bit

Holder Bit

Advice Do not remove the GE cover.


P-VRZR- 021

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

[4] Regulating valve removal


Regulating valve Socket wrench

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 -

DISASSEMBLY [5] TCV (timing control valve) removal


(1) Remove the TCVs torx bolts.
Tool name
TCV torx bolts (2)

Holder Bit

Part no 157915-9820 157915-9600

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

[6] E E P R O M , T P S ( t i m e r p i s t o n sensor) and timer cover removal


(1) Remove the EEPROM.

P-VRZR- 311

- 21 -

DISASSEMBLY
(2) Remove the TPS bolts.
TPS bolts (2) TPS

P-VRZR- 026

Timer spring Adjusting shim TPS

(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.

TPS standard point shim

Core rod

P-VRZR- 027

O-ring (large)

Torx bolts (2)

(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

Tool name Socket wrench

Part no 157914-3600

Remarks

CPV holders (4)

P-VRZR- 029

Gaskets (4) Distributor head CPV holders (4)

(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

(3) Remove the plug using a hexagon wrench (SW14mm).


Hexagon wrench Plug

P-VRZR- 031

Snapring Distributor head Shim

(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 -

DISASSEMBLY [8] Distributor head removal


Holder Bit Distributor heads torx bolts (4)

(1) Remove the distributor heads torx bolts.


Tool name Holder Bit Part no 157915-9820 157915-9600 T30 Remarks

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.

Control sleeve Washer

P-VRZR- 034

Holder Bit Forked plate

Torx bolts (2) Rotor shaft assembly

[9] Forked plate and rotor shaft assembly removal


(1) Remove the forked plate.
Tool name Holder Bit Part no 157915-9820 157915-9301 T20 Remarks

Note: The force of the rotor shaft spring is acting on the forked plate. Use care during removal.
P-VRZR- 035

- 24 -

DISASSEMBLY
Rollers

Rotor shaft assembly Clip

Roller shoes Spring

(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

Advice Do not disassemble the plunger from the rotor shaft.

[10] Snapring removal


Hook Pin Snapring

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

[11] Drive shaft removal


Drive shaft

Remove the drive shaft, the washer and the seal ring.

Seal ring Washer


P-VRZR- 038

- 25 -

DISASSEMBLY
Cam ring

[12] Cam ring removal


Position the bearing on the drive side and remove the cam ring.

Bearing

P-VRZR- 039

Slot Slider

[13] Timer piston removal


Remove the timer piston and the slider. Advice Do not drop the slider. Assemble the timer piston so that the slot is positioned toward the EEPROM installation position.

Timer piston

EEPROM installation position

P-VRZR- 040

[14] Bearing removal


Button Holder Bearing

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

[15] Feed pump removal


(1) Remove the feed pumps torx bolts.
Tool name Holder Bit Part no 157915-9820 157915-9201 T15 Remarks

Long torx bolts (3)

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.

Feed pump holder Chamfer Pump housing

(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

Pins Feed pump

P-VRZR- 043

Pump housing

(6) Remove the pump housing assembled with the feed pump holder from bracket C.

Bracket C

P-VRZR- 044

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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.

Pump housing Feed pump

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

Advice Always store the feed pump in the assembled state.

P-VRZR- 046

- 28 -

COMPONENT INSPECTION 1. PREPARATION


Check all disassembled parts for wear and damage and repair or replace any parts that cannot be reused with new parts. Always replace all gaskets and O-rings, etc, with new parts. Do not reuse them.

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 -

COMPONENT INSPECTION 2. INSPECTION [1] Pump housing


(1) Replace the pump housing if it is worn due to the action of the feed pump rotor, the plate or the TCV.

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

Tool name Service kit

Part no 149500-0420 (9 443 613 486)

Remarks

[2] Oil seal


Replace the oil seal if the lip is damaged or worn. Advice Refer to [3] Oil seal removal below for the removal procedure. Refer to [4] Oil seal installation below for the installation procedure.

Oil seal

Oil seal lip


P-VRZR- 050

[3] Oil seal removal


(1) Insert the collet into the oil seal.
Tool name Collet
Oil seal

Part no

Remarks

157928-4100 For 25 shaft dia 157928-4120 For 25 shaft dia

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

Press Outer surface

[4] Oil seal installation


Pump housing

(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.

[5] Feed pump assembly


(1) Replace the feed pump assembly if the inside surface of the liner is peeling or gnawed due to plate contact. (2) Replace the feed pump assembly if the inside edge of the liner is marked. (3) Replace the feed pump assembly if the rotor or plate is rusted or gnawed.

Plate Cover Rotor Liner

P-VRZR- 054

[6] Drive shaft assembly


(1) Replace the drive shaft assembly if the drive key or the feed pumps drive side key groove is damaged. (2) Replace the drive shaft assembly if the taper is scratched or worn. (3) Replace the drive shaft assembly if the thread is damaged. (4) Replace the drive shaft assembly if the shaft or oil seal contact surface is worn. (5) Replace the drive shaft assembly if the washer contact surface is peeling, gnawed or scorched.

Drive shaft assembly


P-VRZR- 055

- 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

Drive shaft assembly

Rotor shaft

P-VRZR- 056

[7] Rotor shaft assembly


Rotor shaft assembly

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.

Roller shoes Washer Rollers


P-VRZR- 057

[8] Cam ring


Cam ring

(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 -

COMPONENT INSPECTION [9] Timer piston


Timer piston

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

[10] Distributor head assembly


(1) Wash the distributor head assembly in clean light oil and lightly move the rotor shaft through its stroke to confirm that it moves smoothly. If the rotor shaft does not move smoothly, replace the distributor head assembly.

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.

Roller shoes Rollers

P-VRZR- 062

(4) Replace the distributor head assembly if there is any play between the cam rings plate and the links pin.

Links pin Plate


P-VRZR- 063

- 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.

GE actuator s ball pin

Control sleeve
P-VRZR- 064

[11] CPV (constant pressure valve) holder


Replace the CPV holder if the CPV holder seat is scratched.
CPV holder

P-VRZR- 065

[12] Plug and rotor shaft spring


(1) Replace the rotor shaft spring if it is rusted or damaged. (2) Replace the plug with a new one if it is burred or the thread is damaged. Advice Always replace the O-ring assembled to the plug with a new one.
Plug Rotor shaft spring

P-VRZR- 066

[13] Regulating valve


Regulating valve

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 -

COMPONENT INSPECTION [14] Magnet valve


Magnet valve

O-ring Spring Armature Gauze filter


P-VRZR- 068

(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

(4) Clean the gauze filter.

[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

GE actuator terminals (reference)


P-VRZR- 070

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

[16] TCV (timing control valve)


TCV

(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

(3) Measure TCV resistance. Reference values:


Terminal nos 5-9 Resistance ( ) 11.00.8 Ambient temperature (C) 235

TCV

P-VRZR- 074

[17] TPS (timer piston sensor)


TPS Timer spring

(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 -

COMPONENT INSPECTION [18] Np sensors


1 (-) 2 (-) 3 (+) (+)

Np sensors

Measure the Np sensors resistances.


Terminal nos 2-3 2-3 Resistance ( ) Remarks 2.15k Main 2.15k Backup

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)

[19] Fuel temperature sensor


Measure fuel temperature sensor resistances. See page 35 for GE actuator terminals. Reference values:
(25, 2) = (fuel temperature, resistance)

Resistance

Terminal nos 7-8

Resistance () 2

Fuel temperature (C) 25

Fuel temperature (C)

P-VRZR- 163

- 37 -

GEAR REASSEMBLY DRIVE GEAR

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

1/3 1/2 1/4 1/1


P-VRZR- 327

Key no 1/1 1/2 1/3 1/4 1/5 1/6 1/8 2 3


Pin Main gear

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

(1) Fully pressfit the pin to the main gear.


Part name Pin Main gear
Pin

Part no Remarks (Mitsubishi part no) 149931-1300 (ME204193) 149931-1910 (ME204369X)

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

Socket head bolts (2)

(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.

Hexagon wrench (SW5)

Rack
P-VRZR- 330

Main gear Base

(5) Align the main gear with the racks and attach it to the center of the base.

P-VRZR- 331

(6) Align the spring with the main gears pin.


Main gear Spring

Part name Spring

Part no Remarks (Mitsubishi part no) 149931-1200 (ME204192)

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

Socket head bolt Wrench

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

Part no Remarks (Mitsubishi part no) 149917-1500 (ME204287) SW5

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

Part no Remarks (Mitsubishi part no) 149931-1600 (ME204236)

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)

Sub-gear Pin Drive gear assembly

P-VRZR- 337

Drive gear assembly

(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

Long pulse plate hole Pulse plate Positioning pin

(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

Bolts (4) Pulse plate Drive gear

(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.

Liner Blade Stamping

1. REASSEMBLY [1] Feed pump assembly reassembly


Rotor
P-VRZR- 077

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 holder

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.

Feed pump holder


P-VRZR- 079

- 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

(9) Temporarily tighten two of the four torx bolts.

Feed pump cover

Short torx bolt

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

Part no 149916-0400 (9 443 612 874) 149916-0300 (9 443 612 873)


Part no 157915-9820 157915-9201 T15

Remarks 1 3
Remarks

Long torx bolt


Tool name Holder Bit

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

Feed pump side

P-VRZR- 084

[2] Bearing reassembly


Button Holder Bearing Pump housing

(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

Advice Ensure the bearing is positioned correctly.


P-VRZR- 085

- 44 -

REASSEMBLY [3] Timer piston reassembly


(1) Assemble the slider in the timer piston.
Timer piston

Slider

P-VRZR- 086

Pump housing

Timer s low pressure side Slider hole

Timer piston

Timer s low pressure side P-VRZR- 087 Cam ring

(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.

[4] Cam ring reassembly


Assemble the cam ring in the pump housing. At this time, insert the cam ring pin into the timer pistons slider hole. Advice Confirm that the timer piston slides smoothly.

Cam ring pin

Pump housing

P-VRZR- 088

- 45 -

REASSEMBLY [5] Drive shaft reassembly


(1) Insert the holder into the bearing. (2) Press the holder button to hold the bearing and pull the bearing into the head. Advice Pull the bearing into the head so that a gap remains between the feed pump cover and the bearing.
Tool name
Holder
P-VRZR- 089

Part no 157928-3620

Remarks

Holder

Spacer

Feed pump cover

Spacer

(3) Insert the spacer into the pump housing.


Tool name Spacer Part no 157928-4700 Remarks

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

Oil seal guide


P-VRZR- 091

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.

Spacer Pump housing

[6] Snapring reassembly


(1) Remove the spacer from the pump housing. Advice Confirm that the drive shafts snapring groove can be seen through the housing window.

P-VRZR- 094

(2) Assemble the snapring to the clip.


Tool name Clip
Clip Snapring

Part no 157928-3120

Remarks

Advice Position the snapring on the clip with the convex face toward the clip.

Convex face

P-VRZR- 095

Clip Drive shafts snapring groove Snapring

(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 -

REASSEMBLY [7] Adjusting drive shaft axial play


(1) Position the distributor head on the pump housing. Advice Do not assemble the O-ring or the control sleeve at this time.

Distributor head

Pump housing

P-VRZR- 097

Holder

Bit Torx bolts (2)

(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

Measuring device Dial gauge

(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

Rotor shaft Distributor head

[8] Selecting the rotor shaft shim


Purpose The rotor shafts axial play is measured and then the play is adjusted to the specified value using the shim. Procedure 1 Adjusting the dial gauges 0 point (1) Insert the rotor shaft into the distributor head. (2) Install the snapring in the rotor shaft s snapring groove. Advice Do not assemble the shim at this time.

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

Part no 157845-8900 157829-3520

Remarks

Adapter Measuring device

For measuring VE cam lift

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

Rotor shaft Adapter

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

Rotor shaft Distributor head

(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 standard point shim Adjusting shim Core rod

[9] TPS and timer cover reassembly


(1) Assemble the TPS to the pump housing. Specified torque: 7.0 ~ 10.0 Nm {0.7 ~ 1.0 kgfm} Advice Do not mistake the positions of the TPS standard point shim and the adjusting shim.

TPS

P-VRZR- 108

Pump housing Timer cover

(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

[10] Pump removal


Remove the pump housing from bracket C.
Pump housing

Bracket C
P-VRZR- 110

- 51 -

REASSEMBLY 2. PRE-STROKE ADJUSTMENT


Cam ring Link plate Pre-stroke adjustment values
Cam lift (mm) Original pre-stroke

Timing link shaft ball pin Control sleeve

Angle of cam rotation ()

Cam link pin

Beginning of cam lift

Beginning of pressure delivery

VRZ pre-stroke (substitute) Timer piston Timing link shaft


P-VRZC- 034 P-VRZR- 315

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

[1] Measuring device installation

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

Tool name Fixing stand Flange

Part no

Remarks

105796-0000 For 20NP 157811-9020 For VRZ

(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

Drive shaft key groove

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

Existing bolts (2)

Drive shaft

Assembly position of measuring devices measuring terminal


P-VRZR- 112

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

Coupling Fixing stand

Specified torque:

167 ~ 185 Nm {17.0 ~ 19.0 kgfm}

P-VRZR- 114

Test bench drive coupling

(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

[2] Setting the 0 point for pre-stroke adjustment


(1) Turn the pump test benchs main switch ON and set the KMA (continuous measuring device) as described below. [Refer to the KMA (continuous measuring device operation manual): Publication No EC18E11091.] Select the angle measurement display Press F6 Select Settings Press Enter Set the direction of rotation Press F2 F2

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

[3] Component reassembly


(1) Rotor shaft reassembly (1) Select a forked plate as described below and then assemble the plate. Selecting a forked plate
Head assembly Cam ring
Forked plate

Forked plate marked G Replaced Replaced Replaced Do not replace (use the installed forked plate)*

Replaced Replaced

Replaced Not replaced Replaced Not replaced

Holder

Bit
P-VRZR- 122

Not replaced Not replaced


Drive shaft

Spring

Rotor shaft pin

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

Tool name Holder

Part no 157915-9820

Remarks

Rotor shaft assembly

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

O-rings (2) Distributor head

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

Torx bolts (4) Holder

Part no 157915-9820 157915-9600

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

Plug Hexagon wrench

(12) Tighten the plug using a hexagon wrench (SW14mm). Specified torque: 20.0 ~ 29.0 Nm {2.0 ~ 3.0 kgfm}

P-VRZR- 129

Dummy holder Cylinder B

Gaskets (4) CPV holders (3) Distributor head

(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

Remarks Part of pipe assembly 157845-9520.

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

Torx bolts (2)

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.)

Small O-ring Large O-ring

Ti m e r cover
P-VRZR- 135

Small O-ring

Pump housing Large O-ring

Torx bolts (2) Bit Holder

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

Timer stroke adjusting shim

Timer spring Core rod Standard point shim Pump housing


P-VRZR- 137

(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.

Pump housing TPS

(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}

Socket wrench Torx bolts (2)


P-VRZR- 138

- 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

GE actuator Seal ring

(7) GE actuator installation (1) Assemble the seal ring (new) to the GE actuator.

P-VRZR- 141

Control sleeve groove

(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

(3) Assemble the GE actuator pin in the control sleeve groove.

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

Torx bolts (6)

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.

Armature Gauze filter


P-VRZR- 147

Magnet valve assembly Spanner

(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

Gaskets (2) Adapter Injection pump

(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

Magnet valve assembly Direct current harness

(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

(13) Remove the plugs.

Socket wrench

P-VRZR- 159

- 67 -

ADJUSTMENT 1. ADJUSTMENT CONDITIONS [1] Test equipment


(1) (2) (3) (4) Pump test bench EPS815 KMA802 Oil cooler (1 687 010 130) Adjustment software operating environment
Windows 2000 PRO (at least Service Pack 2.0) English language version; Control Panel - Regional Options, Your locale: English (United Kingdom or United States) Personal computer equipped with Pentium CPU (clock speed at least 333 MHz) At least 128 MB usable memory At least 20 MB space Resolution: at least 1027 x 768, number of display colors: high color minimum (16 bit) CD-ROM drive, floppy disk drive At least 2 communication ports (2 necessary for controller assembly) Mouse, keyboard

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.

[2] Fuel piping


(1) Injection system piping diagram
Nozzle and nozzle holder assembly (1 688 901 035) Tubes Cooling unit

Injection tubes

Joint assembly (157641-6820)

Injection pipes (157808-4720)

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

Overflow measurement hose

1/5 1/1 Multi-way cock 1/2

1/4 1/3 1/6 1/2 1/5

1/7 Test oil hose

Temperature sensor cable

Pump chamber pressure measurement hose


P-VRZR- 391

- 69 -

ADJUSTMENT [3] Wiring outline


(1) Controller assembly wiring
Injection pump

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

(2) Wiring connections inside controller unit

PC COM2 COM1

VRZ & COVEC-F (ROM) CONTROLLER


AC 100 - 120V 200 - 240V ROM lamp AC socket

RS232C COM2 25 pin

RS232C COM2 9 pin

ROM writer

ROM cable

ROM

ECU lamp DC 5V Constant power supply

4D56 (COVEC-F) ECU FCV line

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

4M41 (VRZ) ECU FCV line FCV line

Main cable

GE CSP TPS TCV TF FCV

FCV switch

Main cable

Power lamp

FCV switch

ECU lamp

WL (COVEC-F) ECU

P-VRZR- 395

- 70 -

ADJUSTMENT [4] Related materials


No. 1 2 Publication No. ED14E-11021 ED14E-11011 Remarks When installing the ECU assembly for the controller unit, refer to the installation instructions included with the controller unit. When installing the adjustment software, refer to the installation manual included with the CD-ROM.

Note: Where updating of adjustment data and inspection data is indicated, copy the data from the ESPI (ZW)s CD-ROM.

- 71 -

ADJUSTMENT 2. CONTROLLER UNIT CONTROLS [1] Front panel


7 8 9 11 10 12

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).

10 Power pilot lamp

- 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

Use and purpose

11 ECU changeover switch

12 Sub-switch 13 ROM pilot lamp 14

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 -

ADJUSTMENT [2] Rear panel

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 -

3. PUMP ADJUSTMENT TOOL FLOW CHART

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

Print result OK Final confirmation

Cancel

Print result

Cancel

Final confirmation

ADJUSTMENT 4. PUMP ADJUSTMENT TOOL MONITOR SCREEN

MC-02 TESTER
Copyright(C) 2001-2003 by Bosch Automotive Systems Corporation

Service tools for pump adjustment Version1.0

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

Workshop name registration

Exit

P-VRZR- 346

No. 1 2 3 4 5 6

Name

Use and purpose

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.

Inspection and adjustment steps monitor screen


Pump information

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

N T Ua-ist Q Pt Qo TF VTPS TPS TA DQ

0 r/min 0.0 deg C


Rotation

44-6666 44-3032 000000000b 00000-000-0000b VRZ 4M41


Right 4 cylinders

19 20 21

V 0.0 mm /st 0.000 MPa 0.0 l/h


3

ECU Mode Pump type

MELCO
Adjustment VRZ(12V)

2001-01-15 11:28:44

V V V mm 0.0 mm3/st

MENU

Part number input

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).

11 Variation between cylinders display

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 -

ADJUSTMENT 6. MANUAL OPERATION DISPLAY Second timing adjustment (manual operation)


Pump adjustment tools for service
MC-02 TESTER

Second timing adjustment (manual operation)

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

ROM COVEC-F MITSUBISHI 12V

VRZ MITSUBISHI 12V

ROM COVEC-F MAZDA 12V

ECU configuration data


Input

GE Soll GE Soll-cor TCV Duty TCV Frequency

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 -

ADJUSTMENT 7. WORKSHOP DISPLAY Second timing adjustment (manual operation)


Pump adjustment tools for service

Workshop name registration

MC-02 TESTER

Workshop name registration

1 2 3 4 5 6

Workshop name Address Telephone Fax Operator's name Password

RBAJ JAPAN 000-000-0000 111-111-1111 sse ****

Input items and select Registration button.

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

WORKSHOP REGISTRATION (1) Select Workshop name registration.

Service tools for pump adjustment Version1.0

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

Workshop name registration

Workshop name Address Telephone Fax Operator's name Password

RBAJ JAPAN 000-000-0000 111-111-1111 sse ****

(2)

Input items and select Registration button.

(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 -

ADJUSTMENT 8. ADJUSTMENT Adjustment sequence


Recording the pump and GE serial numbers

See page 81 [1]

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]

Pump chamber pressure adjustment

Standard injection quantity point adjustment Pump chamber pressure confirmation

TPS zero setting

Timer stroke and characteristic confirmation Non-injection confirmation

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

See page 90 [14] See page 90 [15] See page 94 (4)

Magnet valve operation confirmation Second timing adjustment Finish

- 80 -

ADJUSTMENT [1] Recording the pump and GE serial numbers


(1) Read and record the 10 digit pump serial number. Advice It is easier to read the pumps serial number before beginning Preparation. Note: Serial number input is used during adjustment mode and inspection mode.

Pump serial number

Pump serial no. under EEPROM

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.

Test oil hose Injection system piping

P-VRZR- 353

ROM harness COM2 COM1

Controller unit Controller assembly harness for VRZ adjustment

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

FCV (magnet valve) ON/OFF switch Sub-switch

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.

[3] Adjustment software set up: preparation


(1) Turn the computer and the monitor power switches ON.

Monitor power switch Computer power switch


P-VRZR- 210

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 -

ADJUSTMENT [4] P a r t n u m b e r confirmation


(1)

input

and

MC-02 TESTER
Copyright(C) 2001-2003 by Bosch Automotive Systems Corporation

Service tools for pump adjustment Version1.0

RBAJ

ROM COVEC-F MITSUBISHI 12V Inspection/adjustment VRZ MITSUBISHI 12V Inspection/adjustment ROM COVEC-F MAZDA 12V Inspection/adjustment

(1) Select the VRZ [Mitsubishi 12V] Inspection/ adjustment button.

Manual operation

Workshop name registration

Exit

P-VRZR- 346

MC-02 TESTER

Part number input

If number input is correct, select Next button. If you need to input a different number, select Clear button.

(2) (3)

Specified part no. (6 digits) Pump part no. (last 6 digits)

446613 443062

Pump serial no. (10 digits) GE serial no. (13 digits)

0880052496 5062008852056

(4) (5)

System specifications
Engine model Rotation Pump cylinders ECU

VRZ_4M41 Right 4 cylinders MELCO

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.

If necessary to proceed after confirmation, push Next button.


1

Menu Back Next

P-VRZR- 359

- 83 -

ADJUSTMENT [5] Warming-up operation


Unit Specification Tolerance Pump information
Specified part no.

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

44-6613 44-3062 0880052496 50620-088-52056 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)

0 r/min 0.0 deg C V 0.0 mm3/st

Pump part no. Pump serial no.

(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)

No. Present step Comment 01 Warm-up

Step name

N 300r/min

Soll 2.80v

Soll-cor 0.00mv

Step status Next

Check for fuel leaks. 01 / 31 02

Sequence Select

After values are input, push Next button.


1000r/min 2.91v 0.00mv 60Hz 100%

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.

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

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)

0 r/min 0.0 deg C V 0.0 mm3/st

Pump part no. Pump serial no.

(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

No. Present step Comment 02 Warm-up Warm-up 02 / 31 03

Step name

N 1000r/min

Soll 2.91v

Soll-cor 0.00mv

(13) (14)

Step status Next

Sequence Select

After values are input, push Next button.


1000r/min 2.91v 0.00mv 60Hz 100%

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 -

ADJUSTMENT [6] P u m p c h a m b e r adjustment pressure

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

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)

0 r/min 0.0 deg C V 0.000 MPa 0.0 I/h V

Pump part no. Pump serial no. GE serial no. Engine model

(3)

Ua-ist Pt Qo TF

Rotation Pump cylinders ECU Mode Pump type

05/04/03 13:22:24
Menu Part number input Frequency 60Hz Duty 100%

Step information

(7) (8)

No. Present step Comment 03

Step status Next

Step name P-cham_ADJ

N 1000r/min

Soll 2.91v

Soll-cor 0.00mv

PT standard point 03 / 31 04

Sequence Select

After values are input, push Next button.


1000r/min 2.91v 0.00mv 60Hz 100%

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

Piston Stopper Adjusting device

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

Measured / input value

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)

0 r/min 0.0 deg C V 0.0 mm3/st 0.0 mm /st


3

Pump part no. Pump serial no. GE serial no. Engine model

[7] Standard injection quantity point adjustment


(1) Confirm that the sequence is 04/31. (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) If Q is as specified, perform steps (9) and (10). If Q is not as specified, adjust as described below. (5) To adjust the fuel injection quantity, loosen the torx bolts so that the GE actuator can move a little. (6) Move the GE actuator in the drive shafts axial direction to adjust the full load injection quantity. (To increase the injection quantity, move the GE actuator toward the distributor head. To decrease the injection quantity, move the GE actuator toward the drive side.) Record the measured injection quantity and the position of the GE actuator to facilitate adjustment. (7) Following adjustment, tighten the torx bolts to the specified torque. Specified torque: 7 ~ 10 N.m {0.7 ~ 1.0 kgf.m} (8) Measure N, T, Q and DQ again on the pump test bench and input the values. (9) Confirm that the Step status field is green. (10) Proceed to the next step.

(3)

Ua-ist Q DQ

Rotation Pump cylinders ECU Mode Pump type

05/04/03 13:23:05
Menu Part number input Frequency 60Hz Duty 100%

Step information

(9) (10)

No. Present step Comment 04

Step status Next

Step name Rough-Q_ADJ

N 1000r/min

Soll 2.91v

Soll-cor 0.00mv

Standard Q adjustment (GE adjustment) 04 / 31 05

Sequence Select

After values are input, push Next button.


1000r/min 2.91v 0.00mv 60Hz 100%

P-cham_ADJ

(1)

P-VRZR- 363

Injection quantity decrease (move GE actuator toward drive side) Move GE actuator to adjust

Injection quantity increase (move GE actuator toward distributor head side)

GE actuator
P-VRZR- 355

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

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)

0 r/min 0.0 deg C V 0.000 MPa 0.0 I/h V

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

Rotation Pump cylinders ECU Mode Pump type

05/04/03 13:23:42
Menu Part number input Frequency 60Hz Duty 100%

Step information

No. Present step Comment 05

(5) (6)

Step status Next

Step name P-cham_ADJ

N 1000r/min

Soll 2.91v

Soll-cor 0.00mv

Reconfirmation of PT standard point 05 / 31 06

Sequence Select

After values are input, push Next button


500r/min 2.50v 0.00mv 60Hz 100%

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

Measured / input value

Unit

Specification

Tolerance

[9] TPS zero setting


Pump information
Specified part no.

(3)

N T Ua-ist VTPS TPS

44-6613 44-3062 0880052496 50620-088-52056 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)

0 r/min 0.0 deg C V V V

Pump part no. Pump serial no. GE serial no. Engine model Rotation Pump cylinders ECU Mode Pump type

(4) (7) (8)

05/04/03 13:24:16 Zero set Step information Step status Next


Sequence Select 06 / 31 07 Present step Comment No. 06 Zero_set Step name N 500r/min Soll 2.50v Menu Soll-cor 0.00mv Part number input Frequency 60Hz Duty 100%

Confirm initial TPS output.

After values are input, push Next button.


100r/min 2.41v 0.00mv 60Hz 100%

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)

Spring TPS output adjustment (TPS standard point shim)

P-VRZR- 137

149653-0200 (9 443 613 473) 149653-0300 (9 443 612 841) 149653-0400 (9 443 613 474)

0.2 0.6 1.0

2.1 2.5 2.9

(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 -

ADJUSTMENT [10] Timer stroke and characteristic confirmation


(1) Confirm that the sequence is 07/31. (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 is within the specifications. (5) Confirm that the Step status field is green. (6) Proceed to the next step. Note: Because the TPS standard point shim was adjusted in Step 06/31, it cannot be changed.

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

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)

0 r/min 0.0 deg C V 0.000 MPa V mm

Pump part no. Pump serial no.

(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

No. Present step Comment 07

(5) (6)

Step status Next

Step name Timer_TA

N 100r/min

Soll 2.41v

Soll-cor 0.00mv

100r/min 07 / 31 08

Sequence Select

After values are input, push Next button.


50r/min 2.41v 0.00mv 60Hz 100%

Timer_TA

(1)

P-VRZR- 366

TPS

Timer stroke adjusting shim

Spring

Pump housing

P-VRZR- 137

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

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)

0 r/min 0.0 deg C V 0.000 MPa V mm

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%

Step information Step status Next


Sequence Select Present step Comment

No. 08

Step name Timer_TA

N 50r/min

Soll 2.41v

Soll-cor 0.00mv

50r/min 08 / 31 09

After values are input, push Next button.


325r/min 1.53v 0.00mv 60Hz 100%

Timer_TA

P-VRZR- 367

Service tools for pump adjustment Adjustment display

[11] Non-injection confirmation


Unit Specification Tolerance Pump information
Specified part no.

Status

Item

Measured / input value

N T

44-6613 44-3062 0880052496 50620-088-52056 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)

0 r/min 0.0 deg C V 0.0 mm3/st 0.0 mm3/st

Pump part no. Pump serial no. GE serial no. Engine model

(3)

Ua-ist Q DQ

Rotation Pump cylinders ECU Mode Pump type

05/04/03 13:35:08
Menu Part number input Frequency 60Hz Duty 100%

Step information

No. Present step Comment 17

(4) (5)

Step status Next

Step name Q_characteristics

N 2300r/min

Soll 0.87v

Soll-cor 0.00mv

Confirm no nozzle injection. 17 / 31 18

Sequence Select

After values are input, push Next button.


1900r/min 3.73v 0.00mv 60Hz 100%

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 -

ADJUSTMENT [12] Injection quantity compensation point adjustment


(1) Confirm that the sequence is 18/31. (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) If the injection quantity is not as specified, press the Soll-cor setting, input the soll compensation voltage and adjust the injection quantity to the specification. (5) Measure the injection quantity and confirm that it is as specified. Advice With the Soll-cor setting, the compensation voltage range differs with the service data or the calculation file. If the compensation voltage range is exceeded, a Reset message is displayed. When the injection quantity is greater than the specification Input a minus to the compensation voltage and input the value When the injection quantity is less than the specification Input the value only to the compensation voltage (6) Confirm that the Step status field is green. (7) Proceed to the next step. Confirm compensation point 9 (Step 19/31) ~ compensation point 1 (Step 27/31) using the same procedure used for compensation point 10 (Step 18/31) above. After adjusting the compensation point 1, press the Next button to automatically proceed to Step 28/31.

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

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)

0 r/min 0.0 deg C V 0.0 mm3/st 0.0 mm3/st

Pump part no. Pump serial no. GE serial no. Engine model

(3)

Ua-ist Q DQ

Rotation Pump cylinders ECU Mode Pump type

(4) (6) (7)

05/04/03 13:36:03 Soll-cor Step information Step status Next


Sequence Select 18 / 31 19 Present step Comment No. 18 Step name Cor-Q_ADJ N 1900r/min Soll 3.73v Menu Soll-cor 0.00mv Part number input Frequency 60Hz Duty 100%

Correction point 10

After values are input, push Next button.


1900r/min 1.53v 0.00mv 60Hz 100%

Cor-Q_ADJ

(1)

P-VRZR- 369

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

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)

0 r/min 0.0 deg C V 0.0 mm3/st 0.0 mm3/st

Pump part no. Pump serial no. GE serial no. Engine model Rotation Pump cylinders ECU Mode Pump type

05/04/03 13:36:43 Soll- cor Step information Step status Next


Sequence Select 19 / 31 20 Present step Comment No. 19 Step name Cor-Q_ADJ N 1900r/min Soll 1.53v Menu Soll-cor 0.00mv Part number input Frequency 60Hz Duty 100%

Correction point 9

After values are input, push Next button.


1000r/min 2.91v 0.00mv 60Hz 100%

Cor-Q_ADJ

P-VRZR- 370

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

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)

Injection quantity input data is outside specification after correction point 1.

Pump cylinders ECU Mode Pump type

[13] Compensation ROM interpolation calculation


Note: In Step 28/31 the adjustment software automatically performs the calculations. If the compensation voltage Soll values are not correct, compensation calculations are not performed and an error is displayed. If an error is displayed, repeat Step 18/31.

05/04/03 13:43:00
Menu Part number input Frequency 60Hz Duty 0%

Step information Step status Next


Sequence Select Present step Comment

No. 28

Step name Q-ROM_CAL

N 0r/min

Soll 0.00v

Soll-cor 0.00mv

Q-ROM intermediate point calculation 28 / 31 29

After values are input, push Next button.


0r/min 0.00v 0.00mv 60Hz 0%

ROM_overwrite

P-VRZR- 371

- 89 -

ADJUSTMENT [14] Writing to the compensation ROM


Unit Specification Tolerance Pump information
Specified part no. Pump part no. Pump serial no. GE serial no. Engine model Rotation

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

44-6613 44-3062 0880052496 50620-088-52056 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)

Injection quantity input data is outside specification after correction point 1.

Pump cylinders ECU Mode Pump type

05/04/03 13:43:34
Menu Part number input Frequency 60Hz Duty 0%

Step information Step status Next


Sequence Select Present step Comment

No. 29

Step name ROM_overwrite

N 0r/min

Soll 0.00v

Soll-cor 0.00mv

Overwrite Q-ROM. 29 / 31 30

After values are input, push Next button.


1000r/min 2.91v 0.00mv 60Hz 0%

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

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

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)

0 r/min 0.0 deg C V 0.0 mm3/st

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

Rotation Pump cylinders ECU Mode Pump type

05/04/03 13:44:15
Menu Part number input Frequency 60Hz Duty 100%

Step information Step status Next


Sequence Select Present step Comment

No. 30 Stop_Q

Step name

N 1000r/min

Soll 2.91v

Soll-cor 0.00mv

Confirm no nozzle injection when the FCV is OFF. 30 / 31 31

After values are input, push Next button.


0r/min 2.91v 0.00mv 60Hz 100%

Q_characteristics

(1)

P-VRZR- 373

FCV (magnet valve) ON/OFF switch

(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

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

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)

0 r/min 0.0 deg C V 0.0 mm3/st

Pump part no. Pump serial no. GE serial no. Engine model

(5)

Ua-ist Q

Rotation Pump cylinders ECU Mode Pump type

(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)

No. Present step Comment 30 Stop_Q

Step name

N 1000r/min

Soll 2.91v

Soll-cor 0.00mv

Step status Next

Confirm no nozzle injection when the FCV is OFF. 30 / 31 31

Sequence Select

After values are input, push Next button.


0r/min 2.91v 0.00mv 60Hz 100%

Q_characteristics

P-VRZR- 373

- 90 -

ADJUSTMENT [16] Second timing adjustment


Sub-switch

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.

Fixing stand Harness connectors


P-VRZR- 375

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

Tool name 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.

Test oil hose

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

Pin Pin hole Rack teeth

Tool name Adjusting device

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

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

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)

0 r/min 0.0 deg C V 0.0 mm /st


3

Pump part no. Pump serial no. GE serial no. Engine model Rotation Pump cylinders ECU Mode

(3) Confirm that the sequence is Step 31/31 (Q characteristics).

0.0 mm3/st

Pump type

05/04/03 13:44:46
Menu Part number input Frequency 60Hz Duty 100%

Step information Step status Next


Sequence Select Present step Comment

No. 31

Step name Q_characteristics

N 0r/min

Soll 2.91v

Soll-cor 0.00mv

Second timing 31 / 31 _

After values are input, push Next button.

Adjustment finished

(3)

P-VRZR- 376

- 94 -

ADJUSTMENT
Nuts (3)

(4) Loosen the injection pump bracket installation nuts.

P-VRZR- 264

FBB plate Bolt preventing drive shaft rotation

(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

Bolt preventing drive shaft rotation

(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

Bolt preventing drive shaft rotation

(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

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

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)

0 r/min 0.0 deg C V 0.0 mm3/st 0.0 mm3/st

Pump part no. Pump serial no.

(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

No. Present step Comment 31

(14) (15)

Step status Next

Step name Q_characteristics

N 0r/min

Soll 2.91v

Soll-cor 0.00mv

Second timing 31 / 31 _

Sequence Select

After values are input, push Next button.

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

Pump serial no. GE serial no.

0880052496 50620-088-52056
N r/min T DegC Uaist V

Test complete

Adjustment necessary

No. Result

ECU values Uasoll Soll-cor TCVF V mv Hz

DTCV %

Measured values Q DQ Pt Qo MPa I/h mm /st mm /st

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.

Intermediate harness Torx bolts (4)

Test oil hose P-VRZR- 273

Q adjustment ROM Bit Holder

(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

Tool name Holder Bit

Part no 157915-9820 157915-9301 T20

Remarks

P-VRZR- 393

Overflow valve Bypass hose

(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

Stand Injection pump

(9) Remove the injection pump from the test bench.

P-VRZR- 275

- 98 -

ADJUSTMENT
(10) Remove the stand from the pump test bench.
Stand

P-VRZR- 276

9. MANUAL OPERATION (SECOND TIMING ADJUSTMENT)


Note: Preparation (Injection pump disassembly, Drive gear installation and Injection pump installation) is the same as that described on pages 93 to 96 for automatic adjustment of second timing.

[1] Second timing adjustment


Sub-switch

(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

(3) Select Manual operation on the menu display.

Service tools for pump adjustment Version1.0

RBAJ

ROM COVEC-F MITSUBISHI 12V Inspection/adjustment VRZ MITSUBISHI 12V Inspection/adjustment ROM COVEC-F MAZDA 12V Inspection/adjustment

(3)

Manual operation

Workshop name registration

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

(4) (6) (7) (8) (5)

Select ECU
ROM COVEC-F MITSUBISHI 12V VRZ MITSUBISHI 12V ROM COVEC-F MAZDA 12V

ECU configuration data


Input

GE Soll GE Soll-cor TCV Duty TCV Frequency Initialize ECU

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

FBB plate Bolt preventing drive shaft rotation

(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}

Bolt preventing drive shaft rotation

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

Bolt preventing drive shaft rotation

(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 -

INSPECTION INSPECTION Inspection sequence


Recording the pump and GE serial numbers

See page 103 [1]

Preparation

See page 103 [2], 104 [3] See page 105 [4]

Part no. input and installation confirmation

Warming-up operation

See page 106 [5]

Pump chamber pressure confirmation

See page 107 [6]

TPS confirmation

See page 107 [7]

Timer stroke confirmation

See page 107 [8] See page 108 [9] See page 108 [10]

Non-injection confirmation

Injection quantity confirmation

Magnet valve operation confirmation Inspection result Finish

See page 109 [11]

See page 110 [12]

- 102 -

INSPECTION [1] Recording the pump and GE serial numbers


(1) Read and record the 10 digit pump serial number. Advice It is easier to read the pumps serial number before beginning Preparation. Note: Serial number input is used during adjustment mode and inspection mode.

Pump serial number

Pump serial no. under EEPROM

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.

Test oil hose Injection system piping

P-VRZR- 353

ROM harness COM2 COM1

Controller unit Controller assembly harness for VRZ adjustment

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

FCV (magnet valve) ON/OFF switch Sub-switch

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.

Monitor power switch Computer power switch


P-VRZR- 210

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 -

INSPECTION [4] P a r t n u m b e r confirmation


(1)

input

and

MC-02 TESTER
Copyright(C) 2001-2003 by Bosch Automotive Systems Corporation

Service tools for pump adjustment Version1.0

RBAJ

ROM COVEC-F MITSUBISHI 12V Inspection/adjustment VRZ MITSUBISHI 12V Inspection/adjustment ROM COVEC-F MAZDA 12V Inspection/adjustment

(1) Select the VRZ [Mitsubishi 12V] Inspection/ adjustment button.

Manual operation

Workshop name registration

Exit

P-VRZR- 346

MC-02 TESTER

Part number input

If number input is correct, select Next button. If you need to input a different number, select Clear button.

(2) (3)

Specified part no. (6 digits) Pump part no. (last 6 digits)

446613 443062

Pump serial no. (10 digits) GE serial no. (13 digits)

5555555555 6666666666666

(4) (5)

System specifications
Engine model Rotation Pump cylinders ECU

VRZ_4M41 Right 4 cylinders MELCO

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.

If necessary to proceed after confirmation, push Next button.


1

Menu Back Next

P-VRZR- 359

- 105 -

INSPECTION [5] Warming-up operation


Unit Specification Tolerance Pump information
Specified part no.

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

44-8813 44-3052 5555555555 66666-666-66666 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)

0 r/min 0.0 deg C V 0.0 mm3/st

Pump part no. Pump serial no.

(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

No. Present step Comment 01 Warm-up

Step name

N 300r/min

Soll 2.80v

Soll-cor 0.00mv

(5) (6)

Step status Next

Check for fuel leaks. 01 / 26 02

Sequence Select

After values are input, push Next button.


1000r/min 2.91v 0.00mv 60Hz 100%

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.

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

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)

0 r/min 0.0 deg C V 0.0 mm3/st

Pump part no. Pump serial no.

(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

No. Present step Comment 02 Warm-up Warm-up 02 / 26 03

Step name

N 1000r/min

Soll 2.91v

Soll-cor 0.00mv

(13) (14)

Step status Next

Sequence Select

After values are input, push Next button.


1000r/min 2.91v 0.00mv 60Hz 100%

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 -

INSPECTION [6] P u m p c h a m b e r confirmation pressure

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

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)

0 r/min 0.0 deg C V 0.000 MPa 0.0 I/h V

Pump part no. Pump serial no. GE serial no. Engine model

(3)

Ua-ist Pt Qo TF

Rotation Pump cylinders ECU Mode Pump type

02/04/03 14:10:05
Menu Part number input Frequency 60Hz Duty 100%

Step information

No. Present step Comment 03

(5) (6)

Step status Next

Step name P-cham_ADJ

N 1000r/min

Soll 2.91v

Soll-cor 0.00mv

Reconfirm PT standard point. 03 / 26 04

Sequence Select

After values are input, push Next button.


500r/min 2.50v 0.00mv 60Hz 100%

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.

Service tools for pump adjustment Adjustment display

[7] TPS confirmation


Unit Specification Tolerance Pump information
Specified part no.

Status

Item

Measured / input value

(3)

N T Ua-ist VTPS TPS

44-6613 44-3062 0880052496 50620-088-52056 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)

0 r/min 0.0 deg C V V V

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)

Step status Next

Push Zero set button. 04 / 26 05

Sequence Select

After values are input, push Next button.


100r/min 2.41v 0.00mv 60Hz 0%

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.

[8] Timer stroke confirmation


Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

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)

0 r/min 0.0 deg C V 0.000 MPa V mm

Pump part no. Pump serial no.

(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

No. Present step Comment 05

(5) (6)

Step status Next

Step name Timer_TA

N 100r/min

Soll 2.41v

Soll-cor 0.00mv

100r/min 05 / 26 06

Sequence Select

After values are input, push Next button.


50r/min 2.41v 0.00mv 60Hz 100%

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.

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

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)

0 r/min 0.0 deg C V 0.000 MPa V mm

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%

Step information Step status Next


Sequence Select Present step Comment

No. 05

Step name Timer_TA

N 100r/min

Soll 2.41v

Soll-cor 0.00mv

100r/min 05 / 26 06

After values are input, push Next button.


50r/min 2.41v 0.00mv 60Hz 100%

Timer_TA

P-VRZR- 381

[9] Non-injection confirmation


Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

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)

0 r/min 0.0 deg C V 0.0 mm /st


3

Pump part no. Pump serial no. GE serial no. Engine model

(3)

Ua-ist Q DQ

Rotation Pump cylinders ECU Mode

0.0 mm3/st

Pump type

02/04/03 14:13:11
Menu Part number input Frequency 60Hz Duty 100%

Step information

No. Present step Comment 15

(4) (5)

Step status Next

Step name Q_characteristics

N 2300r/min

Soll 0.87v

Soll-cor 0.00mv

Confirm no nozzle injection. 15 / 26 16

Sequence Select

After values are input, push Next button.


1000r/min 2.91v -34.18mv 60Hz 100%

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

Service tools for pump adjustment Adjustment display

[10] Injection quantity confirmation


Unit Specification Tolerance Pump information
Specified part no.

Status

Item

Measured / input value

N T

44-8813 44-3052 5555555555 66666-666-66666 VRZ_4M41 Right 4 cylinders MELCO Adjustment VRZ (12V)

0 r/min 0.0 deg C V 0.0 mm3/st 0.0 mm3/st

Pump part no. Pump serial no. GE serial no. Engine model

(3)

Ua-ist Q DQ

Rotation Pump cylinders ECU Mode Pump type

02/04/03 14:13:47
Menu Part number input Frequency 60Hz Duty 100%

Step information

No. Present step Comment 16

(4) (5)

Step status Next

Step name Cor-Q_INSP

N 1000r/min

Soll 2.91v

Soll-cor -34.18mv

Correction point 8 16 / 26 17

Sequence Select

After values are input, push Next button.


1900r/min 3.73v 34.18mv 60Hz 100%

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.

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

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)

0 r/min 0.0 deg C V 0.0 mm3/st 0.0 mm3/st

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%

Step information Step status Next


Sequence Select Present step Comment

No. 16

Step name Cor-Q_INSP

N 1000r/min

Soll 2.91v

Soll-cor -34.18mv

Correction point 8 16 / 26 17

After values are input, push Next button.


1900r/min 3.73v 34.18mv 60Hz 100%

Cor-Q_INSP

P-VRZR- 383

- 108 -

INSPECTION
Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

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)

0 r/min 0.0 deg C V 0.0 mm3/st

Pump part no. Pump serial no.

[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%

Step information Step status Next


Sequence Select Present step Comment

No. 26 Stop_Q

Step name

N 1000r/min

Soll 2.91v

Soll-cor 0.00mv

Confirm no nozzle injection when the FCV is OFF. 26 / 26 _

After values are input, push Next button.

Inspection finished

(1)

P-VRZR- 384

FCV (magnet valve) ON/OFF switch

(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

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

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)

0 r/min 0.0 deg C V 0.0 mm3/st

Pump part no. Pump serial no.

(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

No. Present step Comment 26 Stop_Q

Step name

N 1000r/min

Soll 2.91v

Soll-cor 0.00mv

(6) (7)

Step status Next

Confirm no nozzle injection when the FCV is OFF. 26 / 26 _

Sequence Select

After values are input, push Next button.

Inspection finished

P-VRZR- 384

- 109 -

INSPECTION [12] Inspection result


Inspection result
Specified part no. Pump part no.

MC-02 TESTER

44-8813 44-3052
Step name N r/min

Pump serial no. GE serial no.

5555555555 66666-666-66666
N r/min T DegC Uaist v

Test complete

Adjustment necessary

No. Result

ECU values Uasoll Soll-cor TCVF V mv Hz

DTCV %

Measured values Q DQ Pt Qo I/h MPa mm /st mm /st

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.

- 110 -

TIGHTENING TORQUES

Units: Nm {kgfm}
P-VRZR- 389

- 111 -

PART NUMBER EXPLANATION 1. INJECTION PUMP ASSEMBLY NUMBER 1 0 9 1 * * - * * * *


(1) (2) (3) (4) (5) (6)

(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

2. BOSCH TYPE NUMBER


NP - VRZ - *
(1) (2) (3)

** E
(4) (5)

****
(6)

R NP * * *
(7) (8)

(1): (2): (3): (4): (5): (6): (7):

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

- 112 -

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