Bomba VE VRZ EE14E-11162 VRZ Service Manual

7/22/2019 Bomba VE VRZ EE14E-11162 VRZ Service Manual

1/117

Pub. No. EE14E-11162

SERVICE MANUAL REPAIR SERVICE& MAINTENANCE

VRZ


2/117

The following marks are used in this service manual to facilitate correct VRZ maintenance.

Advice Procedures that must be performed to enable the best possible VRZmaintenance.

Note Information assisting in the best possible VRZ maintenance.

MEANINGS OF MARKS

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!! Improper maintenance can result in injury and property damage.CAUTION


3/117

FOREWORDThe contents of the manual, includingillustrations, drawings and specifications werethe latest available at the time of printing.

The right is reserved to make changes inspecifications and procedures at any timewithout notice.

BOSCH K.K.Sales Automotive Aftermarket Division

This service manual describes the disassembly,inspection, reassembly and adjustment of theVRZ (radial plunger system position-control

distributor type fuel injection pump).Refer to the separate service manuals listedbelow to facilitate VRZ type injection pumpmaintenance.This manual is intended for use by vehiclemaintenance technicians or persons with anadequate knowledge of injection pumps.

Service manual Publication number

VRZ Construction and Operation EE14E-11150

INJECTION PUMP TEST BENCH 10NP & 20 NP, Operation EC18E-11081

CONTINUOUS MEASURING DEVICE ZCM & ZCD, Operation EC18E-11091

CONTROLLER ASSEMBLY MC-02, FOR VRZ & COVEC-F EC14E-11022

WITH EEP-ROM, Operation

MC-02 TESTER SOFTWARE, ADJUSTMENT AND INSPECTION ED14E-11011

DATA, FOR VRZ AND COVEC-F WITH EEP-ROM, Installation

ECU ASSEMBLY, ADJUSTMENT AND INSPECTION DATA, ED14E-11021FOR VRZ AND COVEC-F WITH EEP-ROM, Installation


4/117


5/117

SERVICE PRECAUTIONS

- 1 -

[1] Carrying the injection pump Never knock or drop the injection pump

when carrying it.

When carrying the injection pump, hold thepump by the bottom of the pump body.

P-VRZR- 320

P-VRZR- 321

P-VRZR- 322

P-VRZR- 323

Pump body

GE actuator

GE actuator

Wire harness

Harness connectors

GE actuator

Wire harness

Injection pump

Injection pump

Never hold the pump by the GE actuator orthe harnesses.Holding the pump by these components mayresult in damage or injury.

CAUTION

[2] Disassembly and reassembly Only the mechanical components of the

injection pump body can be disassembledand reassembled.

AdviceDo not disassemble the GE actuator otherthan directed in this manual. The GE actuator consists of electrical

components. Do not damage them.

When cleaning the injection pump, do notclean the GE actuator, the harnesses, or theharness connectors using fuel oil. Use onlyclean waste cloth.

Injection pump


6/117

SPECIAL TOOLS

- 2 -

20 21

2233

34

24

26

8

11

12

28

23

14

15

25

16

37

36

17

35

18

19

31

32

30

10

9

5

3, 4

1

2

13

27

29

6

7

1. DISASSEMBLY, INSPECTION AND REASSEMBLY TOOLS[1] Tool use locations

P-VRZR- 324


7/117


8/117

SPECIAL TOOLS

- 4 -

Keyno

RBAJ part no Bosch part no Part name Qty Remarks

30

31

32

33

34

35

36

37

157915-9700

157928-4800

157917-4920

157977-8000

026512-1640

157971-0500

157924-8520

157928-4400

9 681 610 686

9 442 612 302

9 681 610 711

9 681 610 829

9 421 617 041

9 443 613 408

9 681 611 028

9 442 612 371

Socket

Plate

Wrench

Adapter

Gasket

Clip

Base

Pliers

1

1

1

1

3

1

1

1

For removing and installing pump support

bracket (T50)

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


9/117


10/117

SPECIAL TOOLS

- 6 -

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


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

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

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

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

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

46

25 75


11/117

SPECIAL TOOLS

- 7 -

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


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

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

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


12/117


13/117


14/117


15/117

SPECIAL TOOLS

- 11 -

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

8. 105793-0020(9 681 610 418)Adjusting device

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

7. 105781-0890(9 680 610 087)Stand

200

11

M10X1.0

M12X1.5


16/117

SPECIAL TOOLS

- 12 -

[3] Adjustment controller assembly breakdown:Key no. 1: 105782-8360 (9 680 610 209)Note:The numbers in brackets below are Bosch part numbers.

Adjustment controller assembly part table (for VRZ)

1:105782-8360(9 680 610 209)

1-1: 157966-4020(9 443 613 446)

1-2: 157966-3720

(9 443 613 456)

1-3: 157966-3820(9 443 613 457)

1-4: 157966-3920

(9 443 613 458)

1-1-1: 157966-4120 (9 443 613 447)

1-1-9: 157966-5100 (9 443 613 455)

1-1-8: 157966-5020 (9 443 613 454)

1-1-7: 157966-4920 (9 443 613 453)

1-1-6: 157966-4820 (9 443 613 452)

1-1-5: 157966-4720 (9 443 613 451)

1-1-4: 157966-4620 (9 443 613 450)1-1-3: 157966-4520 (9 443 613 449)

1-1-2: 157966-4420 (9 443 613 448)

Keyno

RBAJ part no Bosch part no Part nameQty

Remarks

1-1 157966-4020 9 443 613 446 CONTROLLER ASSY 1

1-1-1 157966-4120 9 443 613 447 Controller unit 1 Checker assy

1-1-2 157966-4420 9 443 613 448 Wire harness 1 Power supply (Japan, USA)

1-1-3 157966-4520 9 443 613 449 Wire harness 1 Power supply (EC)

1-1-4 157966-4620 9 443 613 450 Wire harness 1 PC: COM1 ~ MC-02

1-1-5 157966-4720 9 443 613 451 Wire harness 1 PC: COM2 ~ MC-021-1-6 157966-4820 9 443 613 452 Wire harness 1 FCV GND harness

1-1-7 157966-4920 9 443 613 453 Main harness 1 Controller-Pump GE

1-1-8 157966-5020 9 443 613 454 Main harness 1 Controller-Pump ROM

1-1-9 157966-5100 9 443 613 455 CD-ROM 1 Software (Overseas Ver.) & (Calibration data)& Manual

1-3 157966-3820 9 443 613 457 ECU assembly 1 For Mitsubishi 4M41 engines

Note:Key number 1 (RBAJ part no.105782-8360, Bosch part no. 9 680 610 209) enables adjustment ofboth VRZ and COVEC-F pumps.With the VRZ, however, only key numbers 1-1 (RBAJ part no. 157966-4020, Bosch part no. 9 443613 446) and 1-3 (RBAJ part no. 157966-3820, Bosch part no. 9 443 613 457) are necessary.


17/117

SPECIAL TOOLS

- 13 -

1-1 157966-4020(9 443 613 446)CONTROLLER ASSY

1-1-1 157966-4120(9 443 613 447)

Controller unit

1-1-4 157966-4620(9 443 613 450)Wire harness

1-1-2 157966-4420(9 443 613 448)Wire harness

1-1-5 157966-4720(9 443 613 451)Wire harness

1-1-6 157966-4820(9 443 613 452)Wire harness

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

1-1-3 157966-4520(9 443 613 449)Wire harness

20002000

2000

1000

2990


18/117


19/117

DISASSEMBLY

- 15 -

161

922

100

101

160

102

878S

925 923

920

912914

90550

22

3537

36

33

65

34

50

11

83

80/7

45

38

931 930

46

3132

3530

62

53

61

50

54 60

51

2018

9

8080/8

1

4243

4140

82

66

108

76

5

15

810S 856S2726

2

910911

3

56

205

17

25

16

55

948 949

110

949

50

111

112

50

130

150/8152

150

153

956

955

151

121

120

122

1. PREPARATION Clean the outside of the injection pump

before disassembly, removing all grease anddirt. Drain the fuel oil from the pump.

Keep the work bench and workshop cleanand tidy.

Before beginning disassembly, recordperformance data for later reference tofacilitate the diagnosis of malfunctions anddefects, if any, in the pump.

2. EXPLODED VIEW

P-VRZR- 326

Lay out the disassembled parts neatly andsequentially on the work bench, labellingthem if necessary, to facilitate laterreassembly.

Prepare a container of clean fuel oil forplungers, delivery valves and other precisionparts.


20/117

DISASSEMBLY

- 16 -

3. ENGINE DRIVE GEAR REMOVAL(1) Fix the injection pump bracket in a vise.

(2) Install wrench B so that it can turn the twogears (ie, the main gear and the sub-gear)clockwise.

(3) Turn the main gear and the sub-gear usingwrench A until they are aligned. Then, inserta bolt through the two gears and tighten itus ing a torque wrench. (T ightentemporarily.)

(4) Remove wrenches A and B and the torquewrench from the drive gear.

(5) Install wrench B so that the main gear andthe 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 tightento the specified torque.

Specified torque: 9 ~ 13 Nm{0.9 ~ 1.3 kgfm}

Note:

The drive gear is divided into the main gear andthe sub-gear.Wrench B is used to prevent drive gear rotation.Wrench A is used to align the main gear andthe sub-gear.

Tool name Part no Remarks

Wrench A 157917-4920

Wrench B 157917-4620

P-VRZR- 300

P-VRZR- 301

Injection pump body

Drive gear

Wrench A

Wrench B

Bolt (M6x1)

P-VRZR- 318

Drive gear

Wrench A

Wrench B

Bolt (M6x1)


21/117

DISASSEMBLY

- 17 -

(8) Remove wrench A.

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

(10) Assemble puller A in the gap between the

drive gear and the bracket and loosely fixthe bolts.

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


Puller 157927-4500 Parts A and B

P-VRZR- 302

P-VRZR- 303

P-VRZR- 305

P-VRZR- 304

Sub-gear

Socket wrench

Bolt

Puller A

Drive shaft

Puller B


22/117

DISASSEMBLY

- 18 -

(12) Tighten the puller bolt to remove the drivegear.

AdviceHold the puller so that it does not drop whenthe gear is removed from the drive shaft.

(13) Remove the drive shaft key.

(14) Remove the nuts (at three locations).

(15) Remove the bracket from the pumphousing and then remove the O-ring.

P-VRZR- 306

P-VRZR- 307

P-VRZR- 319

Drive gear

Bolt

Key

Nuts (3)

Bracket

O-ring

Drive shaft


23/117


24/117

DISASSEMBLY

- 20 -

[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.AdviceDo not lose the armature spring.

[3] GE actuator removal(1) Remove the GE actuators torx bolts and

spring washers.

(2) Remove the GE actuator.

AdviceDo not damage the ball pin (refer to the GEactuator on page 35).


Holder 157915-9820

Bit 157915-9600 T30

[4] Regulating valve removalAssemble the socket wrench to theregulating valve and then remove theregulating valve.


Socket wrench 157913-7000

AdviceDo not remove the GE cover.

P-VRZR- 020

P-VRZR- 021

P-VRZR- 023

P-VRZR- 022

Magnet valve

Grommet Nut

GE actuator Torx bolts (6)

Spring washers (6)

GE coverHolder

Bit

GE actuator

S o c k e t

wrenchRegulating valve


25/117


26/117

DISASSEMBLY

- 22 -

(3) Remove the TPS, the adjusting shim, thetimer spring, the core rod and the TPSstandard point shim.

AdviceLabel the TPS standard point shim and thetimer stroke adjusting shim to avoidmistaking them at reassembly.

P-VRZR- 027

TPS

Adjusting shim

TPS standard point shim Core rod

(2) Remove the TPS bolts.

P-VRZR- 026

TPS bolts (2)

TPS

Timer spring

(4) Remove the timer cover and the O-rings

(large and small).

P-VRZR- 028


Holder 157915-9820

Bit 157915-9600 T30

O-ring (small)

Timer cover

O-ring (large)

Bit Holder

Torx bolts (2)


27/117

DISASSEMBLY

- 23 -



P-VRZR- 029

[7] CPV (constant pressure valve)holder and plug removal

(1) Loosen the CPV holders.

(2) Remove the CPV holders and the gaskets.AdviceLine up the removed CPV holders in orderto match the positions (A, B, C, D) on thedistributor head from where they wereremoved.

P-VRZR- 030

(3) Remove the plug using a hexagon wrench

(SW14mm).

P-VRZR- 031

Socket wrench

Gaskets (4)

CPV holders (4)

Plug

Hexagon wrench

Distributor head

CPV holders (4)

(4) Remove the snapring and shim from therotor shaft.

Note:The shim is easier to remove after removing thedistributor head assembly.

P-VRZR- 032

Shim

Snapring

Distributor head


28/117


29/117

DISASSEMBLY

- 25 -

(2) Remove the rotor shaft assembly andremove the rollers and roller shoes from therotor shaft.

Advice Do not drop the rollers or the roller shoes.

Do not change the roller and roller shoecombinations.

(3) Assemble the clip to prevent the plungerfrom dropping out of the rotor shaftassembly.

P-VRZR- 036

[11] Drive shaft removalRemove the drive shaft, the washer and theseal ring.

P-VRZR- 038

[10] Snapring removalInsert the hooks pin into the snaprings holeand tighten the butterfly nut to pull out thesnapring.

P-VRZR- 037


Hook 157928-5820

Rotor shaft assembly

Spring

Roller shoes

Rollers

Snapring

Hook

Drive shaft

Seal ring


Clip 157971-0500

Washer

Pin

Clip

AdviceDo not disassemble the plunger from the

rotor shaft.


30/117


31/117


32/117


33/117


34/117


35/117


36/117

COMPONENT INSPECTION

- 32 -

[7] Rotor shaft assembly(1) Replace the distributor head assembly if any

of the rotor shaft assemblys sliding partsare peeling, gnawed or scorched.

(2) Replace the washer with a new one if it isworn.

P-VRZR- 056

P-VRZR- 057

P-VRZR- 058

Timer slider

Cam ring


Drive shaft assembly

(6) Replace the drive shaft assembly if there isany play between the rotor shafts ball pinand the drive shaft.

[8] 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 timerslider.

Rotor shaft

(3) Replace the cam ring if the cam rings camprofile is peeling or scorched.

P-VRZR- 059

Radial plungers

Rollers

Roller shoes

Cam ring

Ball pin

Pin

Washer


37/117


38/117


- 34 -

[11] CPV (constant pressure valve)holder

Replace the CPV holder if the CPV holderseat is scratched.

P-VRZR- 064

P-VRZR- 065

P-VRZR- 066

CPV holder

Control sleeve

GE actuators ball pin

(5) Assemble the GE actuators ball pin to thecontrol sleeve groove. If there is any play,replace the distributor head assembly.

[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.AdviceAlways replace the O-ring assembled to theplug with a new one.

[13] Regulating valveReplace the regulating valve assembly if thepiston inside the regulating valve is sticking.

Advice Always replace the O-rings with new

ones. Do not disassemble the regulating valve

unless necessary.

P-VRZR- 067

Plug Rotor shaft spring

Regulating valve

O-rings

Stopper


39/117


- 35 -

6

5

3

2

1

12

11

10

9

8

7

4

[14] Magnet valve(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.AdviceAlways replace the O-ring with a new one.(3) Check the magnet valve resistance and

replace the magnet valve assembly if theresistance is not as specified.

P-VRZR- 068

P-VRZR- 069

P-VRZR- 070

[15] GE actuator(1) Replace the GE actuator if the ball pin isworn or if the plating is damaged or peeling.

(2) Assemble the GE actuators ball pin in the

control sleeve groove and confirm that thereis no play.If there is any play between the ball pin andthe control sleeve, replace the GE actuatoror the distributor head assembly or both.

Control sleeve

GE actuator

GE actuator

GE actuator terminals (reference)

Terminal no. Name Remarks

1 FCV Black, magnet valve

2 Blank -

3 Blank -

4 CSP (OSC) Yellow

5 TCV (+) Red

6 GE (+) White

7 TF (+) Blue, fuel temperature (+)

8 CSP (MDL) Red

9 TCV (-) Black

10 GE (-) Green

11 TF (-) Grey, fuel temperature (-)12 CSP (GND) BlackP-VRZR- 312

Magnet valve

O-ring

Spring

Armature

Ball pin (4) Clean the gauze filter.

Terminalnos

Resistance( )

Ambient temperature(C)

1 - GND 8.01.2 235

Gauze filter


40/117


41/117


- 37 -

P-VRZR- 314

[18] Np sensorsMeasure the Np sensors resistances.

Np sensors

[19] Fuel temperature sensorMeasure fue l temperature sensorresistances.See page 35 for GE actuator terminals.Reference values:

Fuel temperature (C)

(k)

3 (+)

2 (-)

1

P-VRZR- 163

Resistance

Terminalnos

Resistance( )

Fuel temperature (C)

7 - 8 2 25

(25, 2) = (fuel temperature, resistance)

Terminal nos Resistance ( ) Remarks

2 - 3 2.15k Main

2 - 3 2.15k Backup

AdviceWhen using a digital circuit tester,resistances cannot be measured unless youhold the minus probe against the No. 2terminal and the plus probe against the No.3 terminal.

(+)

(-)


42/117


43/117


44/117

GEAR REASSEMBLY

- 40 -

P-VRZR- 333

P-VRZR- 334

P-VRZR- 335

P-VRZR- 336

(7) Attach the sub-gear to the main gear. Atthis time, hook the sub-gears pin to thespring.

(8) Align the wrench with the sub-gears holesand attach it to the sub-gear.

Tool name Part no RemarksWrench 157917-4920

(9) Turn the wrench counterclockwise to align

the main gears teeth with the sub-gearsteeth.

(10) Screw in the socket head bolt (SW5) totighten the sub-gear to the main gear.


Part namePart no

(Mitsubishi part no)Remarks

Socket head bolt149917-1500(ME204287)

SW5

CAUTION

Socket head bolts cannot be reused.

(11) Hold the snapring open using pliers andinstall it in the main gears snapring groove.

Part namePart no

(Mitsubishi part no)Remarks

Snapring 149931-1600(ME204236)


Pliers 157928-4400

Socket head bolt

Wrench

Sub-gear

PliersSnapring

Main gear

Base

Pin

Sub-gear

Spring

Sub-gear

Wrench


45/117


46/117

REASSEMBLY

- 42 -

The reassembly of the VRZ type injection pumpis basically the reverse of the disassemblyprocedure. The following describes the standardreassembly procedure.Always replace gaskets and O-rings with new

ones.1. REASSEMBLY[1] Feed pump assembly reassemblyAdvice 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 injectionpump rotation. Install the liner so thatthe applicable mark can be seen whenthe liner is viewed from the head side.


Feed pump holder 157928-4320

P-VRZR- 077

P-VRZR- 078

Blade

Liner

Rotor

(2) Position the feed pump cover notch towardthe GE actuator side and insert the feedpump assembly into the pump housing untilthe feed pump is contacting the housing.

(3) Hold the feed pump holder so that it doesnot move and turn the pump housing upsidedown.

P-VRZR- 079

Cover

Feed pumpFeed pump holder

Feed pump holder

Pump housing

Stamping

Pins

Chamfer

Notch

Notch

(1) Position the feed pump assembly and the

cover on the feed pump holder. Assemblethe holder pins in the feed pump holes (2).

AdviceAlign the feed pump cover notch with thefeed pump holder chamfer.

Notch


47/117


48/117

REASSEMBLY

- 44 -

P-VRZR- 083

P-VRZR- 084

(10) Remove the set screw and install the othertwo torx bolts.

(11) Tighten the four torx bolts uniformly. (Oneof the four torx bolts does not screw intothe pump housing.)

Specified torque: 3.0 ~ 4.0 Nm{0.3 ~ 0.4 kgfm}


Holder 157915-9820

Bit 157915-9201 T15

For feed pump Part no Remarks

Short torx bolt149916-0400

(9 443 612 874)1

Long torx bolt149916-0300

(9 443 612 873)3

Holder

Bit

Head

side

Feed pump

side

Seal ring

AdviceMove the rotor backward and forward andleft and right with your finger and check thatit moves smoothly. If it does not movesmoothly, loosen the feed pump cover andthen retighten it to the specified torque.

(12) Insert the seal ring into the feed pump

cover.AdviceBe careful with the assembly orientation ofthe seal ring and ensure it is securelyassembled to the feed pump cover.

[2] Bearing reassembly(1) Assemble the holder to the bearing and

press the holder button (to hold the bearing).(2) Install the bearing in the pump housing.

P-VRZR- 085


Holder 157928-3620

Holder

Bearing

Pump housing

Button

AdviceEnsure the bearing is positioned correctly.


49/117

REASSEMBLY

- 45 -

[3] Timer piston reassembly(1) Assemble the slider in the timer piston.

P-VRZR- 086

(2) Assemble the timer piston and slider in thepump housing.

Advice

Align the slider hole with the timer pistonhole.

The slider is assembled in the timer withthe hole positioned toward the GEactuator side.

Note:The timer pistons low pressure side ispositioned toward where the Q adjustment ROMis installed.

P-VRZR- 087

[4] Cam ring reassemblyAssemble the cam ring in the pump housing.At this time, insert the cam ring pin into thetimer pistons slider hole.

AdviceConfirm that the timer piston slidessmoothly.

P-VRZR- 088

Slider

Timer piston

Timer piston

Pump housing

Cam ring

Pump housing

Cam ring pin

Slider hole

Timers low pressure side

Timers low pressure side


50/117

REASSEMBLY

- 46 -

[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.AdvicePull the bearing into the head so that a gapremains between the feed pump cover andthe bearing.

(3) Insert the spacer into the pump housing.

P-VRZR- 089

P-VRZR- 090

P-VRZR- 091


Spacer 157928-4700

(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.Key

Shim

Oil seal guideDrive shaft

(6) Confirm that the seal ring is inserted intothe feed pump cover (see bottom figure ofpage 44).

(7) Align the drive shaft key with the feed pumprotor key groove and insert the drive shaftinto the feed pump.

AdviceInsert the drive shaft gently into the feedpump while turning it clockwise and counterclockwise to align the key with the keygroove.

P-VRZR- 092


Holder 157928-3620Holder

Spacer

Drive shaft

Pump housing

Spacer

Bearing


Oil seal guide 157928-4000For 25 diashaft

U-shaped

ring

Feed pump cover


51/117

REASSEMBLY

- 47 -

;

;

[6] Snapring reassembly(1) Remove the spacer from the pump housing.

AdviceConfirm that the drive shafts snapringgroove can be seen through the housingwindow.

P-VRZR- 094

(8) Lightly tap the drive shaft using a plastichammer to assemble the drive shaft with theend fully protruding from the drive side.

Advice When tapping the drive shaft with the

plastic hammer, ensure no burrs or dirtremain on the shaft.

Insert the drive shaft so that the end ofthe drive shaft is 1 ~ 2 mm higher thanthe end of the inner cam (when viewedfrom above).

After assembling the drive shaft, confirmthat the shaft rotates smoothly.

(3) Position the snapring in the drive shafts ringgroove and push it straight down.

(4) Remove the clip from the snapring and usethe end of the clip to push the snapring fullyinto the groove.

AdviceConfirm that the snapring is fully insertedinto the groove and that the drive shaft canbe rotated.

(2) Assemble the snapring to the clip.

P-VRZR- 095

P-VRZR- 096

P-VRZR- 093


Clip 157928-3120

Snapring

Clip

Plastic hammer

Pump housing

Spacer

Snapring

Clip AdvicePosition the snapring on the clip with theconvex face toward the clip.

Drive shaft

Inner cam

Drive shafts snapring groove

Convex face

1 ~ 2 mm


52/117

REASSEMBLY

- 48 -

P-VRZR- 097

[7] Adjusting drive shaft axial play(1) Position the distributor head on the pump

housing.AdviceDo not assemble the O-ring or the controlsleeve at this time.

(2) Install and tighten two diametrically opposedtorx bolts of the four to install the distributorhead.



Measuring device 105782-4530

P-VRZR- 100

P-VRZR- 099

(3) Attach the measuring device to the drive

shaft.(4) Attach the dial gauge to the measuring

device.

P-VRZR- 098

(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 thetable on the following page and exchangethe shims until the axial play is as specified.(Refer to page 49.)

AdviceIf the axial play varies greatly from the

specified value, repeat procedure [5] on page46 and [6] on page 47.


Holder 157915-9820

Bit 157915-9600 T30

Measuring device

Distributor head

Pump housing

Torx bolts (2)

Bit

Holder

Drive shaft

Measuring device

Dial gauge

Drive shaft


53/117

REASSEMBLY

- 49 -

(7) Remove the dial gauge.(8) Remove the measuring device handle and

attach the extractor.

(9) Screw in the extractor to remove themeasuring device.

P-VRZR- 102

(10) Remove the torx bolts from the distributor

head.(11) Remove the distributor head from the

pump housing.


Extractor 157926-2421

P-VRZR- 101

P-VRZR- 103

RBAJ part no Bosch part no Thickness (mm)

149602-0000149602-0100149602-0200149602-0300149602-0400149602-0500149602-0600149602-0700149602-0800149602-0900149602-1000

9 443 612 8099 443 612 8109 443 612 8119 443 612 8129 443 612 8139 443 612 8149 443 612 8159 443 612 8169 443 612 8179 443 612 8189 443 612 819

1.901.952.002.052.102.152.202.252.302.352.40

[8] Selecting the rotor shaft shimPurposeThe rotor shafts axial play is measured and thenthe play is adjusted to the specified value usingthe shim.

Procedure 1 Adjusting the dial gauges 0point

(1) Insert the rotor shaft into the distributor head.

(2) Install the snapring in the rotor shaftssnapring groove.AdviceDo not assemble the shim at this time.

Snapring

Rotor shaft

Extractor

Distributor head

Pump housing

Distributor head

Measuring device

Shims


54/117

REASSEMBLY

- 50 -

P-VRZR- 104

(3) Attach the adapter to the head and thenattach the measuring device to the adapter.

P-VRZR- 105


Adapter 157845-8900

Measuringdevice

157829-3520 For measuringVE cam lift

(4) Pull the rotor shaft fully to the left and setthe dial gauge to the 0 position.

P-VRZR- 106

Procedure 2 C a l c u l a t i n g t h e s h i m

thickness(1) Push the rotor shaft fully to the right and

measure the full stroke from the dial gauge.AdviceThe rotor shafts groove must not catch onthe head.

P-VRZR- 107

(2) Select a shim using the formula below.Shim thickness = full stroke0.2 (mm)

RBAJ part no(key no. 53)

Bosch part noThickness

(mm)

149720-0000149720-0100149720-0200149720-0300

9 443 612 8519 443 612 8529 443 612 8539 443 612 854

2.12.22.32.4

(3) Install the selected shim and the snapring

to the rotor shaft.(4) After inserting the shim, confirm that thestroke is as specified. If not as specified,repeat Procedure 1 and Procedure 2.Specified stroke: 0.20.1 mm

Adapter

Measuring device

Head

Rotor shaft

Head

Head

Adapter

Adapter

Measuring device

Measuring device

Shim Snapring

Rotor shaft

Distributor head

Rotor shaft

Rotor shaft

Dial gauge


55/117

REASSEMBLY

- 51 -

P-VRZR- 108

(5) Remove the dial gauge and adapter fromthe head.

(6) Remove the snapring.

[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}AdviceDo not mistake the positions of the TPSstandard point shim and the adjusting shim.

(2) Assemble the O-rings (at two locations) and

then assemble the high pressure side timercover on the pump housing.


P-VRZR- 109

P-VRZR- 110

[10] Pump removalRemove the pump housing from bracket C.

Pump housing

TPS

Pump housing

Pump housing

Timer cover

Bracket C

TPS standard point shim

Adjusting shim

Core rod


56/117

REASSEMBLY

- 52 -

Cam ring

Timer piston

Cam link pin

Link plate

Timing link shaft ball pin

Control sleeve

Timing link shaft

Angle of cam rotation ()

VRZ pre-stroke (substitute)

Beginning of

cam lift

Beginning of pressure

delivery

Originalpre-stroke

Caml

ift(mm)

Pre-stroke adjustment values

2. PRE-STROKE ADJUSTMENT

Fundamentally, pre-stroke is the amount of lift from the cams bottom dead center position to thebeginning of pressure delivery position. With the VRZ pump, however, because it is not possibleto 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 thecam 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.)

P-VRZC- 034 P-VRZR- 315


57/117

REASSEMBLY

- 53 -

(4) Install the pre-stroke measuring device.Specified torque: 10.0 ~ 14.0 Nm

{1.0 ~ 1.4 kgfm}


Measuring device 105782-4540

[1] Measuring device installation

P-VRZR- 111

P-VRZR- 112

Drive shaft key position

for 4M41 model engine

Measuring device Drive shaftExisting bolts (2)

CAUTION

The pump test bench drive motor must beturned OFF.

Injury or damage may result if the pump testbench drive motor is turned ON.

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 shaftgroove.

P-VRZR- 316

FlangeInjection pump

Fixing stand Tool name Part no Remarks

Fixing stand 105796-0000 For 20NP

Flange 157811-9020 For VRZ

(1) Temporarily attach the fixing stand to thepump test bench and attach the injectionpump to the fixing stand.

(2) Align the key groove with the standardcylinder Bs pressure delivery cam positionas shown at left.

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 thestandard cylinder B, however, measure thepre-stroke for this cylinder.

I f the dr ive shaft key groove and themeasuring devices measuring terminal arenot aligned, pre-stroke cannot be adjustedfrom cylinder B when the rotor shaft is

assembled.

Assembly position

of measuring

devices measuring

terminal

Drive shaft key groove

Measuring device

Measuring terminal


58/117

REASSEMBLY

- 54 -

(6) Move the fixing stand to assemble thecoupling teeth to the pump test bench drivecoupling.

AdviceEnsure approximately 1 mm axial clearancebetween the coupling and the drive coupling.

P-VRZR- 116

P-VRZR- 115

(7) Securely tighten the fixing stand installation

bolts and nuts and the drive coupling sockethead bolt to fix the injection pump to thepump test bench.

(8) Turn the pump test bench flywheel using thelever to confirm that the injection pumprotates smoothly.

(5) Assemble the key to the drive shaft. Alignthe coupling with the key, assemble it to thedrive shaft and then fix it using the nut.


P-VRZR- 114

Fixing stand

Coupling

Fixing stand

Test bench drive coupling

Flywheel

Lever

CAUTION

Remove the lever after operating theflywheel.Operating the test bench without removing

the lever can cause serious injury anddamage the test bench.


Coupling 157847-0820 Shaft dia 25


59/117

REASSEMBLY

- 55 -

[2] Setting the 0 point for pre-strokeadjustment

(1) Turn the pump test benchs main switch ONand set the KMA (continuous measuringdevice) as described below. [Refer to theKMA (continuous measuring deviceoperation manual): Publication No EC18E-11091.]

Select the angle measurement display

Press F6 Select Settings

Press Enter Set the direction of rotationPress F2

P-VRZR- 164

Flywheel

P-VRZR- 118

Monitor display example

Dial gauge

angle measurement

F1 F2 F3 F4 F5 F6 F7 F8

1 2 4 5 63 7 8 10 11 129

(2) Turn the pump test bench flywheel in the

direction of pump rotation to find thestandard cylinders bottom dead centerposition on the measuring device dial gauge.(Refer to the data sheet for the standardcylinder.)

(3) Zero the dial gauge.(4) Turn the flywheel in the direction of rotation

so that the dial gauge reading is 0.7 mm.

P-VRZR- 117

Dial gauge

F2


60/117

REASSEMBLY

- 56 -

P-VRZR- 119

(5) Set the continuous measuring device asdescribed below.Press F2 Press both shift keys (press bothshift keys at the same time to activate anglecontrol) the monitor will display the dialog

position control unit error: control circuitopen) Press Enter the monitor displaywill change to(---.-) Press F6 Selectzero point setting Press Enter. (Thepump test bench angle measurement is nowset at 0.)

(6) To absorb backlash, turn the flywheel backat leas t 10 and then set the anglemeasurement display at 355 (ie, turn theflywheel back 5).

(7) Check that the dial gauge reading is 0mm.(8) Set the continuous measuring device asdescribed below.Press F6 Select zero point setting

Press Enter.(The pump test bench angle measurementis now set at 0.)

AdviceDo not alter the continuous measuringdevice angle measurement menu after this.Note:

The beginning of cam lift position is now set.

Flywheel

Measuring device

P-VRZR- 165

Monitor display example

(9) Remove the measuring device.

a n g l e m e a s u r e m e n t

F 1 F 2 F 3 F 4 F 5 F 6 F 7 F 8

1

0 . 0

5 6 2 4 3

P-VRZR- 120


61/117

REASSEMBLY

- 57 -

P-VRZR- 122


Holder 157915-9820

Bit 157915-9301 T20

(10) Remove the TPS from the pump housing.(11) Remove the timer cover from the pump

housing.

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 marked G

Replaced Replaced Replaced

ReplacedNot

replacedReplaced

Not replaced Replaced Replaced

Not replacedNot

replacedDo not replace (use theinstalled forked plate)*

* If the installed forked plate fork is worn,assemble a forked plate marked G.(Refer to the table on page 67.)


(2) Rotate the drive shaft so that the rotor shaft

pin is positioned toward the GE actuator asshown at left.

Note:The rotor shaft does not contact the forked pate.(3) Remove the clip from the rotor shaft.

P-VRZR- 123

Forked plate

Holder Bit


Clip 157971-0500

Timer cover

Pump housing

TPS

Clip

Spring

(4) Assemble the radial plungers, the rollershoes and the rollers to the rotor shaft.

(5) With the spring assembled to the rotor shaft,

assemble the rotor shaft assembly to thedrive shaft groove.

AdviceDo not drop the roller shoes or the rollers.


Drive shaft

Rotor shaft

Rotor shaft pin


62/117

REASSEMBLY

- 58 -

P-VRZR- 124

(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 ispositioned toward the head.

(3) Assemble the distributor head assembly tothe rotor shaft.

(4) Tighten diagonally opposed torx bolts to

loosely install the distributor head.AdviceDo not tighten the distributor head assembly.Leave it loose.(5) Assemble the distributor head assembly to

the pump housing.AdviceMove the timer piston to align the forkedplate groove with the distributor headassembly pin.

P-VRZR- 126

(6) Move the timer piston and confirm that thecontrol sleeve rotates, and then graduallytighten 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, thecontrol sleeve will not move smoothly, the pinmay not engage the plate when the head istightened, and either the plate or the pin may

be damaged.(8) Tighten the torx bolts until the distributor

head assembly is securely tightened to thepump housing.

P-VRZR- 125

Distributor head

Pump housing

Distributor head

Control sleeve

Large chamfer Small chamfer

Head side

Pump housing

Distributor head

Torx bolts

O-rings (2)


63/117

REASSEMBLY

- 59 -

(10) Assemble the shim and snapring to therotor shaft.

(11) Install the plug to the distributor head

together with a new O-ring.

P-VRZR- 128

(9) Install the other two torx bolts and thentighten all four torx bolts to the specifiedtorque.


(12) Tighten the plug using a hexagon wrench

(SW14mm).Specified torque: 20.0 ~ 29.0 Nm

{2.0 ~ 3.0 kgfm}

(3) CPV holder reassembly(1) Assemble the gaskets and CPV holders to

the distributor heads cylinders A, C and D.AdviceThe CPV holders must be reassembled tothe distributor head in their original positionsA, C and D marked on the head.(2) Assemble the dummy holder and gasket to

the distributor heads cylinder B.

P-VRZR- 130

P-VRZR- 127

P-VRZR- 129


Holder 157845-9500Part of pipe assembly157845-9520.


Holder 157915-9820

Bit 157915-9600 T30

Torx bolts (4)

Holder

Bit

Snapring

Shim

O-ring

CPV holders (3)

Distributor head

Plug

Plug

Gaskets (4)

Hexagon wrench

Dummy holder

Cylinder B


64/117


65/117

REASSEMBLY

- 61 -

(5) Timer cover and TPS (timer pistonsensor) reassembly

(1) Assemble the timer cover and the small andlarge O-rings (new) to the high pressure side.(See below for the assembly procedure.)

P-VRZR- 135

P-VRZR- 136

(2) Push the small O-ring securely into the pumphousing using your finger.

(3) Push the large O-ring securely into the timer

cover using your finger and install the timercover using the torx bolts.


(6) Secure the TPS to the pump housing usingthe torx bolts and a socket wrench (M6).


P-VRZR- 137

(4) Assemble the TPS standard point shim, the

core rod, the timer spring and the timerstroke adjusting shim in the pump housing.

AdviceDo not mistake the assembly positions of theTPS standard point shim and the timer strokeadjusting shim.(5) Assemble the TPS to the pump housing.AdviceEnsure the O-rings are not damaged.

P-VRZR- 138


Holder 157915-9820

Bit 157915-9600 T30Holder

Bit

T imer

cover

Large O-ringSmall O-ring

Torx bolts (2)

Pump housing

TPS

Core rod

Timer spring

Timer stroke

adjusting shim

O-ring

Pump housing

Timer

cover

Pump housing

Socket wrench

TPS

Torx bolts (2)

Standard point shim

Large O-ring

Small O-ring


66/117


67/117

REASSEMBLY

- 63 -

(3) Assemble the GE actuator pin in the controlsleeve groove.

(4) Move the GE actuator in an axial directionas shown by the arrow in the figure at leftand 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 sleevegroove. If it will not move, remove theGE actuator and again insert the pin intothe groove.

(5) Move the GE actuator fully toward the full

side (ie, the head side).AdviceIf the GE actuator is positioned toward thedrive shaft side, it may not be possible tomeasure the pre-stroke.

(6) Secure the GE actuator to the pump housingusing the torx bolts.

AdviceTighten diagonally opposed torx boltsgradually and uniformly to the specifiedtorque.Specified torque: 7.0 ~ 10.0 Nm

{0.7 ~ 1.0 kgfm}


Holder 157915-9820

Bit 157915-9600 T30

P-VRZR- 143

P-VRZR- 144

P-VRZR- 145

P-VRZR- 146

GE actuator

GE actuator

GE actuator pin

Holder

Pump housing

Torx bolts (6)

Bit


68/117

REASSEMBLY

- 64 -

(8) Magnet valve assembly installation(1) Install the magnet valve assembly to the GE

actuator.AdviceEnsure the filter is installed securely.

P-VRZR- 147

P-VRZR- 148

(2) Tighten the magnet valve assembly using atorque spanner.

Specified torque: 20.0 ~ 25.0 Nm

{2.0 ~ 2.5 kgfm}

(9) Pre-stroke adjustment

(1) Connect the fuel hose to the injection pumpusing the adapter.

P-VRZR- 149

P-VRZR- 150

(2) Install plugs to where the distributor headand GE actuator overflow valves wereremoved.

AdviceInstall any suitable plugs to maintain pumpchamber air tightness.


Adapter 157977-8000

Gasket 026512-1640

Magnet valve assembly

Magnet valve assemblyGE actuator

Spanner

Hose

Adapter

Injection pump

Plugs

Gaskets (2)

Armature

O-ring

Spring

Gauze filter

Magnet valve


69/117

REASSEMBLY

- 65 -


Pipe assembly 157845-9520

(3) Remove cylinder Bs delivery valve holderand assemble the pipe assembly to cylinderB.

(5) Turn the pump test bench drive switch ON.

(6) Supply test oil to the injection pump at thespecified pressure (20.0 kPa {0.2 kgf/cm2}).

AdviceLeave the drive switch ON. Do not turn thedrive switch OFF until pre-stroke adjustmenthas been completed.

P-VRZR- 153

(7) Turn the pump test bench flywheel aboutone turn in the specified direction of rotationusing the lever and use the anglemeasurement display to confirm that it turnssmoothly.

P-VRZR- 154

P-VRZR- 152

P-VRZR- 151

(4) Connect the direct current harness to themagnet valve.

Advice

Magnet valve supply voltage 12V specification: 12V

Injection pump

Lever

Flywheel

Magnet valve assembly

Pipe assembly

Direct current harness

Cylinder B


70/117


71/117

REASSEMBLY

- 67 -

Forked plates for 4 cylinders

(12) Tighten the CPV holder using a socketwrench.




P-VRZR- 159

(11) Remove the pipe assembly from cylinder

B and replace it with the CPV holder.Replace the gasket at the same time.

P-VRZR- 158

CPV holder

(13) Remove the plugs.

RBAJ part no Bosch part no Stamping Pre-stroke variation ()

149615-0001 9 443 612 824 A -3.03

149615-0101 9 443 612 825 B -2.50

149615-0201 9 443 612 826 C -1.97

149615-0301 9 443 612 827 D -1.43

149615-0401 9 443 612 828 E -1.07

149615-0501 9 443 612 829 F -0.54

149615-0601 9 443 612 830 G 0

149615-0701 9 443 612 831 H 0.54

149615-0801 9 443 612 832 I 1.07

149615-0901 9 443 612 833 J 1.43

149615-1001 9 443 612 834 K 1.97

149615-1101 9 443 612 835 L 2.50

149615-1201 9 443 612 836 M 3.03

Plugs

Socket wrench

CPV holder

Cylinder B


72/117

ADJUSTMENT

- 68 -

1. ADJUSTMENT CONDITIONS[1] Test equipment(1) Pump test bench EPS815(2) KMA802(3) Oil cooler (1 687 010 130)(4) Adjustment software operating environment

[2] Fuel piping(1) Injection system piping diagram

Nozzle and nozzle holder assembly (1 688 901 035) Tubes

Joint assembly (157641-6820)Injection pipes (157808-4720) P-VRZR- 390

Cooling unit

Injection tubes

Windows OSWindows 2000 PRO (at least Service Pack 2.0) English language version;Control Panel - Regional Options, Your locale: English (United Kingdom or United States)

Clock speed Personal computer equipped with Pentium CPU (clock speed at least 333 MHz)

Memory At least 128 MB usable memory

Hard disk At least 20 MB space

Display Resolution: at least 1027 x 768, number of display colors: high color minimum (16 bit)

Drive devices CD-ROM drive, floppy disk drive

Additional devicesAt least 2 communication ports (2 necessary for controller assembly)Mouse, keyboard

Note:Refer to the Installation Manual, MC-02 TESTER SOFTWARE, ADJUSTMENT AND INSPECTIONDATA, Publication No. ED14E-11011, for details of personal computer settings and softwareinstallation procedures.


73/117

ADJUSTMENT

- 69 -

Key no RBAJ part no Bosch part no Part name Qty Remarks

1

1/1

1/2

1/3

1/4

1/5

1/6

1/7

157971-1020

157971-1100

026512-1640

029711-2180

157971-1000

017211-2010

157986-8100

026510-1340

9 443 613 442

9 443 613 443

9 421 617 041

9 442 610 444

9 443 613 444

9 442 611 983

9 443 613 445

9 442 610 043

Piping assembly

Bolt

Gasket

Eye

Adapter

Hose clip

Hose

Gasket

-

1

6

2

1

2

1

1

For VRZ overflow fuel piping

For distributor head overflow







Piping outline

Overflow measurement hose

P-VRZR- 391

(2) Fuel piping

Multi-way cock

Test oil hose

Temperature sensor cable

1/2

1/2

1/1

1/41/5

Pump chamber pressure

measurement hose

Pressure gauge

1/3

1/6

1/5

1/7


74/117

ADJUSTMENT

- 70 -

[3] Wiring outline(1) Controller assembly wiring

(2) Wiring connections inside controller unit

PC

COM2 COM1

RS232CCOM225 pin

RS232CCOM29 pin

ROM writer

ECUlamp

ECUlamp

ECUlamp WL

(COVEC-F)ECU

4M41(VRZ)ECU

4D56(COVEC-F)

ECU

ROMcable

Maincable

Maincable

Maincable

ROM

GE

CSP

TPS

TCV

TF

FCV

FCV lineFCV line

FCVswitch

FCV switch

FCV lineFCV switch

Selectorswitch

12

3

4

0

Sub-switch

ROMlamp

DC 5VConstant

power supply

DC 24VConstant

power supply

DC 12VConstant

power supply

Powerlamp

Main powerswitch

ACsocket

AC100 - 120V200 - 240V

VRZ & COVEC-F (ROM) CONTROLLER

Injectionpump

P-VRZR- 395

P-VRZR- 392

ROM harness

(157966-5020)

Personal computer

Tool connection 232C cable

Connection: straight connection

(157966-4620)

Tool connection 232C cable

Connection: cross connection (2 pin, 3 pin cross)

(157966-4720)

Dsub 9 pin

Injection pump

Main harness

(157966-4920)

Dsub 25 pin

Dsub 7 pin

VRZ and COVEC-F

controller unit

Dsub 9 pin

Earth to injection pump

or pump test bench

To AC100V - AC120V or

AC200V - 240V power source

(157966-4420 or 157966-4520)

Intermediate harness

(157966-2421) Intermediate harness

(157966-5720)

FCV GND harness

(157966-4820)


75/117

ADJUSTMENT

- 71 -

No. Publication No. Remarks

1 ED14E-11021When installing the ECU assembly for the controller unit, refer to the installationinstructions included with the controller unit.

2 ED14E-11011When installing the adjustment software, refer to the installation manual included with theCD-ROM.

[4] Related materials

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


76/117


77/117

ADJUSTMENT

- 73 -

Keyno

Name Use and purpose

11 ECU changeover switch

Turn to align with ECU in use.0: All OFF1: No. 1 ECU

2: No. 2 ECU3: No. 3 ECU4: Spare ECU

12 Sub-switchPower 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.

13 ROM pilot lamp Green lamp lights when ROM in use.

14ROM wire harness connectingterminal

For connecting injection pump's ROM harness connector to ROM controllerusing wire harness.

If you smell any unusual smell or see smoke or sparks when using the controller unit, turn thepower 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 causeimproper resistor contact inside the controller unit, preventing proper operation.

Before turning the power switch ON, confirm that the wire harnesses are properlyconnected.

CAUTION


78/117

ADJUSTMENT

- 74 -

Keyno

Name Use and purpose

1 AC100V - 120V power orAC 200V - 240V power terminal

Connect to AC100V - 120V, 50/60Hz power source orAC 200V - 240V power source, 50/60Hz.

2 Main switch (breaker)Controller unit power switch.

Turn ON when in use (position at 'I'). Position at 'O' to turn OFF.

3D-sub 9 pin cable connection(COM1)

Connects RS232C cable to personal computer (for GE).

4D-sub 25 pin cable connection(COM2)

Connects RS232C cable to personal computer (for Q-ROM)

[2] Rear panel

If you smell any unusual smell or see smoke or sparks when using the controller unit, turn thepower OFF immediately and stop using the controller unit.Fire may result if you continue to use the controller unit.

CAUTION

CE

4

2

3

1

Advice

Do not use the controller unit with oily hands. The oil may stick to the dials and causeimproper resistor contact inside the controller unit, preventing proper operation.

Before turning the power switch ON, confirm that the wire harnesses are properlyconnected.

P-VRZR- 345


79/117

-

75-

2. ECU selection

[1] 4D56

[2] 4M41

[3] WL[4] Manual operation

[5] Workshop name registration

[6] Exit

Part no. input

[1] Adjustment

[2] Inspection

Agreement

[1] or [2] or [3] [4] [5]

Disagreement

1. Password input

Input item

[1] Workshop name

[2] Address

[3] Telephone[4] Fax

[5] Operator's name

[6] Password

Push [MENU] button(= Registration change

completed)

Step 1-XX Adjustment

StepXX + 1 ROM compensation

StepXX + 2 ROM writing

Adjustment

Step 1-XX Inspection

Inspection

Adjustment result

OK

Repeatmeasurement

Print result Cancel

Final confirmation

Pre-check 1.

Manual operation

Inspection result

OK Repeatmeasurement

Print result Cancel

OK

Final confirmation

Select "Registration" butto

Confirmation

Workshop name registrati

P-VRZR-396


80/117

ADJUSTMENT

- 76 -

Exit

Workshop name registration

Manual operation

ROM COVEC-F MITSUBISHI 12VInspection/adjustment

VRZ MITSUBISHI 12VInspection/adjustment

ROM COVEC-F MAZDA 12VInspection/adjustment

RBAJService tools for pump adjustment Version1.0Copyright(C) 2001-2003 by Bosch Automotive Systems Corporation

MC-02 TESTER

4. PUMP ADJUSTMENT TOOL MONITOR SCREEN

No. Name Use and purpose

1 4D56 model engine's COVEC-F typeinjection pump inspection / adjustment key

Select for inspection / adjustment of COVEC-F injection pump forMitsubishi 4D56 model engine

2 4M41 model engine's VRZ type injectionpump inspection / adjustment key

Select for inspection / adjustment of VRZ injection pump forMitsubishi 4M41 model engine

3 WL model engine's COVEC-F typeinjection pump inspection / adjustment key

Select for inspection / adjustment of COVEC-F injection pump forMazda WL model engine

4 Manual operation key For adjusting injection pump and engine's installation timing

5 Workshop registration key For workshop registration

6 Exit key To exit adjustment software

5

4

3

6

2

1

P-VRZR- 346


81/117

ADJUSTMENT

- 77 -

5. PUMP ADJUSTMENT TOOL MONITOR SCREEN OUTLINEInspection and adjustment step screen

Pump adjustment tools for service Input part no.Inspection and adjustment steps

monitor screen

0N r/min44-666644-3032

000000000b00000-000-0000b

VRZ 4M41

VRZ(12V)

MELCO

Pump information

MENU

2001-01-15 11:28:44

0.0T

V

Sequence

No. STEP N

03

03 / 32

1000rpm

Soll

2.91v

Soll-cor

0.00mv

TCVF

60Hz

DTCV

100%

04 500rpm 2.50v 60Hz 0%

0.000

0.0

Pt MPa

Qo l/h

TF V

0.0Q

VTPS V

TPS V

TA mm

0.0DQ

Ua-ist

deg C

mm /st3

Rotation

ECU

Right

4 cylinders

Mode

Pump type

Adjustment

Part number input

Zero set

Soll-cor

Step information

Step status

Next

Comment

Select

PT standard point

After values are input, push 'Next' button.

P_cham_ADJ

mm /st3

215

9

8

4

3

7

6

2

1

14

10

15

11

16

12

17

13

18

20

19

22

23

24

25

Only items necessary for each

step are displayed.

Back Next

Circled numbers indicate fields

where input is necessary.

P-VRZR- 347

No. Name Use and purpose

1 Pump speed input N: pump speed Input the pump's speed.

2 Test oi l temperature input T: test oi l temperature Input the test oi l temperature.

3 Actual control sleeve position voltagedisplay

U soll: actual control sleeve positionvoltage

Displays actual control sleeve position voltage.

4 Pump injection quantity input Q: pump injection quantity Input pump's injection quantity.

5 Pump chamber pressure input Pt: pump chamber pressure Input pump's chamber pressure.

6 Pump overflow quantity input Qo: pump overflow quantity Input pump's overflow quantity.

7 TF output display TF: fuel temperature Displays fuel temperature output voltage.

8 VTPS output display VTPS: voltage at 0 mm timer stroke Displays VTPS output voltage (voltage at 0 mm timer stroke).

9 TPS output display TPS: timer piston sensor output voltage Displays TPS (timer piston sensor) output voltage.

10 TA output display TA: timer stroke Displays TA (timer stroke) output.

11 Variation between cylinders display DQ: variation between cylinders Input pump's variation between injection quantities.

12 Zero setting key TPS output voltage at TA = 0 mm can be set at 0 V.

13 Target control sleeve position

compensation voltage key

Any control sleeve position can be set by setting the compensation

voltage.14 NEXT key To set at next step.

15 Keys for moving to next or previous step To set at any step ( BACK, NEXT).

16 Menu key To set at MENU display.

17 Part number input key To set at part number input display.

18 Step status display Displays step status. Changes from red to green when all itemsare within specifications.

19 Part number, serial number display Displays pump information part number (specifi cation, pump) andserial number (pump, GE).

20 Specification display Displays pump information specifications.

21 Measurement mode display Displays pump information measurement mode (inspection,adjustment).

22 Measurement date display Displays date and time of measurements.

23 Status display Displays step status. Green: within specifications; red: outside ofspecifications.

24 Current step display Displays current step items.

25 Next step display Displays next step's items.


82/117

ADJUSTMENT

- 78 -

GE Soll

Item UnitValue

Item UnitValue

ECU reader data

ECU configuration data

1. Values must be input for GE soll, TCV Duty and TCV Frequency.2. Np values do not appear at VRZ pump adjustment.

Input

Select ECU

GE Vist V

Item UnitValue

VTPS Vist

Item UnitValue

r/minNpTF deg C

V

GE Soll-cor mV

TCV Duty %

TCV Frequency Hz

Initialize ECU

Menu

Manual operationMC-02 TESTER

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

6. MANUAL OPERATION DISPLAYSecond timing adjustment (manual operation)

Pump adjustment tools for service Second timing adjustment (manual operation)

No. Name Remarks

1 Control sleeve position actual voltagedisplay

Displays actual control sleeve position voltage.

2 Control sleeve position target voltagedisplay

By operating the input keys, the control sleeve position can be setfor the engine specified in No. 5.

3 Initialize ECU Clear display values

4 MENU Displays MENU screen.

5 Select ECU Select the ECU for the engine.

1

2

3

4

5

P-VRZR- 348


83/117

ADJUSTMENT

- 79 -

Menu Registration

Input items and select Registration button.

Workshop name RBAJ

Address JAPAN

Telephone 000-000-0000

Fax 111-111-1111

Operator's name sse

Password ****

Workshop name registrationMC-02 TESTER

Exit


Manual operation




RBAJService tools for pump adjustment Version1.0Copyright(C) 2001-2003 by Bosch Automotive Sys tems Corporation

MC-02 TESTER

Menu Registration

Input items and select Registration button.

Workshop name RBAJ

Address JAPAN

Telephone 000-000-0000

Fax 111-111-1111

Operator's name sse

Password ****

Workshop name registrationMC-02 TESTER

7. WORKSHOP DISPLAYSecond timing adjustment (manual operation)

Pump adjustment tools for service Workshop name registration

No. Name Remarks

1 Workshop name Input comany name.

2 Address Input company address.

3 Telephone Input telephone number.

4 Fax Input fax number.

5 Operator's name Input operator's name.

6 Password Input password and change password.

7 MENU Can be used to set MENU display.

8 Registration For keeping registered items.

1

3

4

56

P-VRZR- 350

7

2

8

(1)

(3)

(2)

P-VRZR- 346

P-VRZR- 350

WORKSHOP REGISTRATION(1) Select Workshop name registration.

(2) Input the company name, etc, in the fieldson the screen.

(3) Click the Registration button.Note:The default password at setup is RBAJ.Input a new password if desired. (The only limitto the number of figures and letters in thepassword is the size of the input field.)


84/117

ADJUSTMENT

- 80 -

8. ADJUSTMENTAdjustment sequence

Preparation

Pre-stroke adjustment

Pump chamber pressure adjustment

Timer stroke and characteristic confirmation

Pump chamber pressure confirmation

Magnet valve operation confirmation

Finish

Standard injection quantity point adjustment

Non-injection confirmation

Injection quantity compensation point adjustment

Compensation ROM interpolation calculation

Writing to the compensation ROM

Second timing adjustment

Part no. input and installation confirmation

Warming-up operation

Recording the pump and GE serial numbers See page 81 [1]

See page 81 [2], 82 [3]

See page 88 [11]

See page 83 [4]

See page 64 (9)

See page 84 [5]

See page 85 [6]

See page 86 [8]

See page 88 [10]

See page 86 [7]

See page 89 [12]

See page 89 [13]

See page 90 [14]

See page 90 [15]

See page 94 (4)

See page 87 [9] TPS zero setting


85/117


86/117

ADJUSTMENT

- 82 -

Password is required to actuate adjustment tools.

Input password and press ENTER key.

Precaution

MC-02 TESTER

(8) Reconfirm that the coupling and the fixingstand bolts and nuts are securely tightened.

(9) Set the 20NP pump test benchs test oiloutlet temperature at 45C.

(10) Set the cooling unit oil delivery pressure

lever at 80 kPa {0.8 kgf/cm2} or less.

(11) Connect the wire harness to the controllerunits 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 powerswitches ON.

(2) Start the Service tools for pump adjustmentsoftware.

(3) Input the password and press the Enter key.AdviceInput the initial default password RBAJ oryour own password.

Fixing stand

FCV (magnet valve) ON/OFF switch

E C U f o r V R Z t y p e

injection pump

Sub-switch

No. 1 ~ No. 4 changeover switch

Monitor power switch

Computer power switch

(3)

P-VRZR- 355

P-VRZR- 397

P-VRZR- 210

P-VRZR- 357


87/117

ADJUSTMENT

- 83 -

Menu

4. Operation sequence

3. Adjustment controller wiring

2. Overflow piping

1. Injection system piping

Back Next

Installation confirmationClick on appropriate itemand explanatory illustration is displayed.

If necessary to proceedafter confirmation, push Next button.

Setup confirmationMC-02 TESTER

Key no.

1

2

3

4

Part name Part no. Note

Injection pipe

Nozzle & nozzle holder assembly

Joint

Injection tube

157808-4720

1 688 901 035

Same as VP44

4

3

2

1

Menu NextClear

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

446613

443062

System specifications

Pump serial no.(10 digits)

GE serial no.(13 digits)

Specified part no.(6 digits)

Pump part no.(last 6 digits)

0880052496

5062008852056

Engine model VRZ_4M41Rotation Right

Pump cylinders 4 cylindersECU MELCO

Mode Adjustment

Part number inputMC-02 TESTER

1. Specified part no.

2. Pump part no.Example:

Full pump no.

109144-3052

104700-0551

Input pump part no.

443052

000551

Pumppart no.

104700-304*

104700-305*

104700-306*

109144-305*

109144-306*

104700-055*

Pumptype OEM

Specified part no.

COVEC-F

VRZ

COVEC-F

003040

003051

003060

008040

008051

008060

44-6613 44-8813

008550000550MAZDA

MITSUBISHI

Adjustment Inspection

Exit


Manual operation




RBAJService tools for pump adjustment Version1.0Copyright(C) 2001-2003 by Bosch Automotive Syst ems Corporation

MC-02 TESTER

[4] P a r t n um b e r i n p u t a n dconfirmation

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

(2) When the dialog shown at left appears, inputthe specified part number (6 digits) andpress Enter.

(3) Input the pump part number (last 6 digits)and press Enter.

(4) Input the pump serial number (10 digits) andpress Enter.

(5) Input the GEs serial number (13 digits) andpress Enter.

(6) Press the Next key.

(7) Confirm that the screen changes to the

injection system piping display.Note:Clicking the different buttons (1. Injection systempiping, 2. Overflow piping, 3. Adjustmentcontroller wiring, and 4. Operation sequence)displays different Setup confirmation screens.

(2)

(3)

(4)

(5)

(1)

(6)

P-VRZR- 346

P-VRZR- 358

P-VRZR- 359


88/117

ADJUSTMENT

- 84 -

Next

Step status

Status Item Unit Specification ToleranceMeasured / input value

0N r/min

deg C

After values are input, push Next button.Sequence

Present stepNo. S tep name N

02

02 / 31

1000r/min

Soll

2.91v

Soll-cor

0.00mv

0.00mv

Frequency

60Hz

Duty

100%Warm-up

03 1000r/min 2.91v 60Hz 100%P-cham_ADJ

Warm-up

Select

Comment

Specifiedpartno.

Pump part no.

Pump serial no.

GE serial no.

Engine model

Rotation

Mode

Pump type

Pump cylinders

ECU

44-6613

44-3062

0880052496

50620-088-52056

VRZ_4M41

Right

Adjustment

VRZ (12V)

4 cylinders

MELCO

Pump information

Step information

Menu Part number input

05/04/03 13:21:45

0.0

0.0

T

Ua-ist V

Q

Service tools for pump adjustment Adjustment display

3mm /st

Next

Step status

Status I tem Unit Specification ToleranceMeasured / input value

0N r/min

deg C



01

01 / 31

300r/min

Soll

2.80v

Soll-cor

0.00mv

0.00mv

Frequency

60Hz

Duty

100%Warm-up

02 1000r/min 2.91v 60Hz 100%Warm-up

Check for fuel leaks.

Select

Comment

Specifiedpartno.

Pump part no.

Pump serial no.

GE serial no.

Engine model

Rotation

Mode

Pump type

Pump cylinders

ECU

44-6613

44-3062

0880052496

50620-088-52056

VRZ_4M41

Right

Adjustment

VRZ (12V)

4 cylinders

MELCO

Pump information

Step information


05/04/03 13:20:52

0.0

0.0

T

Ua-ist V

Q


3mm /st

[5] Warming-up operation(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.AdviceIf U ist values are not as specified, pressthe 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 severaltimes, the GE may be faulty.

(7) Confirm that the sequence is 02/31.

(8) Run the injection pump at the specifiedspeed N (see figure at left).

(9) Measure N, T and Q on the pump test benchand 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.

CAUTION

If there are any fuel leaks, if there is noinjection or if any unusual noises occurduring operation, stop test bench operationimmediately and inspect the pump.

(12) Confirm that the injection pump isoperating normally.

(13) Confirm that the Step status field is green.(14) Proceed to the next step.AdviceBecause the test oil temperature takeslonger to increase in cold weather, turn thepump test bench on earlier.

P-VRZR- 360

P-VRZR- 361

(2)

(5)

(7)

(6)

(13)

(14)

(4)

(9)


89/117


90/117

ADJUSTMENT

- 86 -

Next

Step status


0N r/min

deg C

After values are input, push Next buttonSequence


05

05 / 31

1000r/min

Soll

2.91v

Soll-cor

0.00mv

0.00mv

Frequency

60Hz

Duty

100%P-cham_ADJ

06 500r/min 2.50v 60Hz 100%Zero_set

Reconfirmation of PT standard point

Select

Comment

Specifiedpartno.

Pump part no.

Pump serial no.

GE serial no.

Engine model

Rotation

Mode

Pump type

Pump cylinders

ECU

44-6613

44-3062

0880052496

50620-088-52056

VRZ_4M41

Right

Adjustment

VRZ (12V)

4 cylinders

MELCO

Pump information

Step information


05/04/03 13:23:42

0.0

0.000

T

Ua-ist V

I/h0.0Qo

TF V

Pt MPa


Next

Step status


0N r/min

deg C



04

04 / 31

1000r/min

Soll

2.91v

Soll-cor

0.00mv

0.00mv

Frequency

60Hz

Duty

100%Rough-Q_ADJ

05 1000r/min 2.91v 60Hz 100%P-cham_ADJ

Standard Q adjustment (GE adjustment)

Select

Comment

Specifiedpartno.

Pump part no.

Pump serial no.

GE serial no.

Engine model

Rotation

Mode

Pump type

Pump cylinders

ECU

44-6613

44-3062

0880052496

50620-088-52056

VRZ_4M41

Right

Adjustment

VRZ (12V)

4 cylinders

MELCO

Pump information

Step information


05/04/03 13:23:05

0.0

0.0

T

Ua-ist V

0.0DQ

Q


mm /st3

3mm /st

[7] Standard injection quantity pointadjustment

(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 asdescribed below.

[ 8 ] P u m p c h a m b e r p r e s s u r e

confirmation(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.

AdviceRecheck the feed pump.

(3)

(1)

(9)

(10)

(3)

(5)

(6)

P-VRZR- 363

P-VRZR- 355

P-VRZR- 364(1)

Injection quantity decrease

(move GE actuator toward drive side)

Injection quantity increase

(move GE actuator toward

distributor head side)

GE actuator

Move GE actuator to adjust

(5) To adjust the fuel injection quantity, loosenthe torx bolts so that the GE actuator canmove a little.

(6) Move the GE actuator in the drive shaftsaxial direction to adjust the full load injectionquantity. (To increase the injection quantity,move the GE actuator toward the distributorhead. To decrease the injection quantity,move the GE actuator toward the drive side.)Record the measured injection quantity andthe position of the GE actuator to facilitateadjustment.

(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 pumptest bench and input the values.

(9) Confirm that the Step status field is green.(10) Proceed to the next step.


91/117


92/117

ADJUSTMENT

- 88 -

Next

Step status


0N r/min

deg C



17

17 / 31

2300r/min

Soll

0.87v

Soll-cor

0.00mv

0.00mv

Frequency

60Hz

Duty

100%Q_characteristics

18 1900r/min 3.73v 60Hz 100%Cor-Q_ADJ

Confirm no nozzle injection.

Select

Comment

Specifiedpartno.

Pump part no.

Pump serial no.

GE serial no.

Engine model

Rotation

Mode

Pump type

Pump cylinders

ECU

44-6613

44-3062

0880052496

50620-088-52056

VRZ_4M41

Right

Adjustment

VRZ (12V)

4 cylinders

MELCO

Pump information

Step information


05/04/03 13:35:08

0.0

0.0

T

Ua-ist V

mm /st3

3

0.0DQ

Q mm /st


Next

Step status


0N r/min

deg C



07

07 / 31

100r/min

Soll

2.41v

Soll-cor

0.00mv

0.00mv

Frequency

60Hz

Duty

100%Timer_TA

08 50r/min 2.41v 60Hz 100%Timer_TA

100r/min

Select

Comment

Specifiedpartno.

Pump part no.

Pump serial no.

GE serial no.

Engine model

Rotation

Mode

Pump type

Pump cylinders

ECU

44-6613

44-3062

0880052496

50620-088-52056

VRZ_4M41

Right

Adjustment

VRZ (12V)

4 cylinders

MELCO

Pump information

Step information


05/04/03 13:20:52

0.0

0.000

T

Ua-ist V

VVTPS

TA mm

Pt MPa


Confirm 50 revolutions (Step 08/31) ~ 1,900

revolutions (Step 16/31) using the sameprocedure used for 100 revolutions (Step 7/31)above.AdviceRepeat Step 06/31 if the timer stroke is notas specified.

[11] Non-injection confirmation(1) Confirm that the sequence is 17/31.(2) Run the inject

Bomba VE VRZ EE14E-11162 VRZ Service Manual

Documents

Transcript of Bomba VE VRZ EE14E-11162 VRZ Service Manual