Bomba VE VRZ EE14E-11162 VRZ Service Manual

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

INSPECTION .................................... 102

SPECIAL TOOLS ................................. 2

TIGHTENING TORQUES ................. 111

1. DISASSEMBLY, INSPECTION AND REASSEMBLY TOOLS .......................... 2 2. ADJUSTMENT TOOLS ........................... 9 DISASSEMBLY................................... 15 1. 2. 3. 4.

Page

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

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.

•

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

Injection pump P-VRZR- 320

GE actuator

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

[2] Disassembly and reassembly

GE actuator

Injection pump

•

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

•

Harness connectors GE actuator

Wire harness Injection pump

P-VRZR- 323

-1-

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.

SPECIAL TOOLS 1. DISASSEMBLY, INSPECTION AND REASSEMBLY TOOLS [1] Tool use locations 18

21

20

31

30

19

32

34

10

22

33

7

9

27

24

6 26

29 13

8

15

11

14

12 37 25

28

36

16

23 3, 4 2 5

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

RBAJ part no

Bosch part no

Part name

Qty

Remarks

1

157944-8521 9 681 610 317 Universal vise

1

Bracket (used together with key nos 2, 3, 4 and 5)

2

157945-2020 9 681 610 812 Bracket

1

For fixing VRZ pump

3

157944-7100 9 681 610 340 Bracket

1

For fixing bracket (key no 2)

4

157944-7200 9 681 610 797 Bracket

1

For fixing bracket (key no 2)

5

010010-2220 9 442 612 366 Bolt

2

For fixing brackets (key nos 3 and 4)

6

157913-7000 0 986 612 682 Socket wrench

1

For removing and installing regulating valve

7

157928-4320 9 442 612 367 Feed pump holder

1

For removing and installing feed pump assembly

8

157914-3600 9 681 610 678 Socket wrench

1

For removing and installing CPV holder

9

157928-4000 9 442 612 368 Oil seal guide

1

For protecting oil seal (shaft dia: φ 25)

10

157928-4120 9 442 612 299 Extractor

1

For removing oil seal (shaft dia: φ 25)

11

157829-3520

1

For measuring rotor's axial play (tool for

9 681 610 171 Measuring device

measuring VE cam lift) 12

157845-8900 9 681 610 626 Adapter

1

Used together with key no 11

13

105782-4530 9 680 610 094 Measuring device

1

For measuring drive shaft play (shaft dia: φ 25)

14

157917-4620 9 681 610 710 Wrench

1

For preventing gear rotation on 4 cylinder pumps

15

157848-2300 9 681 611 027 Oil seal guide

1

For installing pump housing oil seal

16

157926-2421 9 681 610 773 Extractor

1

For removing drive gear and coupling

17

157927-4500 9 443 613 008 Puller

1

For removing drive gear

18

157928-5820 9 443 613 397 Hook

1

For removing drive shaft snapring

19

157928-3120 9 442 612 297 Clip

1

For installing drive shaft snapring

20

157928-3620 9 442 612 298 Holder

1

For removing and installing bearing

21

157928-4200 9 442 612 369 Guide

1

For centering feed pump cover

22

157928-4500 9 442 612 300 Set screw

1

For centering feed pump's threaded holes

23

157928-4700

1

For positioning ball bearing

24

105782-4540 9 680 610 095 Measuring device

1

For measuring pre-stroke

25

157847-0820 9 442 612 370 Coupling

1

For driving pump (shaft dia: φ 25)

26

157915-9820 9 681 610 687 Holder

1

For SW6.35 bit

27

157915-9201 9 681 610 684 Bit

1

For removing and installing feed pump (T15;

9 442 612 301 Spacer

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)

-3-

SPECIAL TOOLS Key no 30

RBAJ part no

Bosch part no

Part name

Qty

157915-9700 9 681 610 686 Socket

1

Remarks For removing and installing pump support bracket (T50)

31

157928-4800 9 442 612 302 Plate

1

For temporarily holding feed pump

32

157917-4920 9 681 610 711 Wrench

1

For turning auxiliary gear

33

157977-8000 9 681 610 829 Adapter

1

For inlet piping

34

026512-1640 9 421 617 041 Gasket

3

For inlet piping

35

157971-0500 9 443 613 408 Clip

1

For fixing plunger

36

157924-8520 9 681 611 028 Base

1

Stand for installing drive gear

37

157928-4400 9 442 612 371 Pliers

1

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

-5-

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

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

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

-6-

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

75

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

-7-

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

-8-

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

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

6

5

9 8

1 7

2

4

3

P-VRZR- 325

-9-

SPECIAL TOOLS [2] Adjustment tool table (1) Bosch Automotive System specifications Key no

RBAJ part no

Bosch part no

1

105796-0000

1 688 010 129 Fixing stand

1

For driving pump; center height: 125mm

2

157808-4720

9 442 612 278 Injection pipe

4

Inner dia φ 1.6 × outer dia φ 6 - length 450mm

3

157641-6820

9 443 612 974 Joint assembly

1

The VP44 adjustment tool Bosch part no

Part name

Qty

Remarks

0 986 611 876 (key no. 4 in the table below) can also be used instead of this tool. 4

157811-9020

9 681 610 453 Flange

1

For fixing pump

5

157829-0820

9 681 610 336 Adjusting device

1

For adjusting regulating valve pressure

6

157971-1020

9 443 613 442 Piping assembly

1

Test oil overflow piping

7

105781-0890

9 680 610 087 Stand

1

For fixing pump at injection timing adjustment

8

105793-0020

9 681 610 418 Adjusting device

1

For injection timing adjustment

9

157845-9520

9 681 610 630 Pipe assembly

1

For pre-stroke and injection timing adjustment

(2) Bosch specifications Key no 1

Bosch part no

Part name

Qty

1 687 010 126 VE pump overflow accessory

Remarks

1

Three-way valve

4

Bosch type X... for VP44 test device,

set 2

1 688 901 035 Nozzle, nozzle holder assembly

orifice φ 0.5 mm 3

1 687 010 130 Cooling unit

1

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

4

0 986 611 876

Joint assembly

1

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.

5

0 986 612 269

Adapter

4

Used together with above joint assembly.

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

- 10 -

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

- 11 -

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

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

Part name

Qty

RBAJ part no

Bosch part no

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-02

1-1-6

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

- 12 -

Remarks

SPECIAL TOOLS

1-1

1-1-1

1-1-4

157966-4020 (9 443 613 446) CONTROLLER ASSY

157966-4120 (9 443 613 447) Controller unit

157966-4620 (9 443 613 450) Wire harness

1-1-2

157966-4420 (9 443 613 448) Wire harness

1-1-3

157966-4520 (9 443 613 449) 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

2000 2990

- 13 -

1-1-9

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

SPECIAL TOOLS

1-3

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

[4] Intermediate harness table Key no

RBAJ part no

Bosch part no

1

157966-5720

2

157966-2421

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

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

Part name

2.

Qty 1

4M41 VRZ GE

1

For 4M41, 4D56 ROM

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

200 1100

- 14 -

Remarks

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

153 150

65

161

121 35

34

50

955

160

33

38

111 112

66

36

949 110

956

120

37 948

150/8 152 151

122

100 22

101

130

878S

50

102

32

949

31

55 56

45

911

30

46

910

35 905

50

11

50

61

62

54

2

50

53

912 3 914

17

51 205

5

60

6 16 9

25

10

8

7

80/7

1

922 41

40 42 43

83

18 20

82 931

80/8

15

930

80 920

27

26

810S

856S

925

923

P-VRZR- 326

- 15 -

DISASSEMBLY 3. ENGINE DRIVE GEAR REMOVAL

Injection pump body

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

P-VRZR- 300

(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.)

Bolt (M6x1)

Wrench A Drive gear

Wrench B

Tool name

P-VRZR- 301

Part no

Wrench A

157917-4920

Wrench B

157917-4620

Remarks

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

Wrench B

(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 N•m {0.9 ~ 1.3 kgf•m}

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

(10) Assemble puller A in the gap between the drive gear and the bracket and loosely fix the bolts.

Bolt

Tool name Puller

Puller A

Part no

Remarks

157927-4500 Parts A and B

P-VRZR- 304

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

Drive shaft Puller B

P-VRZR- 305

- 17 -

DISASSEMBLY (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.

Drive gear

Bolt P-VRZR- 306

(13) Remove the drive shaft key. Key

Drive shaft P-VRZR- 307

(14) Remove the nuts (at three locations). (15) Remove the bracket from the pump housing and then remove the O-ring.

Bracket

Nuts (3)

O-ring

P-VRZR- 319

- 18 -

DISASSEMBLY 4. DISASSEMBLY [1] Injection pump installation

Remove overflow valve from here.

(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

(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 A’s and bracket B’s bolts.

Universal vise

Bolts (2)

Tool name

Bracket A Position at front.

Bracket B

Bracket C P-VRZR- 017

Part no

Universal vise

157944-8521

Bracket A

157944-7100

Bracket B

157944-7200

Bracket C

157945-2020

Bolt

010010-2220

Remarks

M10x1.5

(4) Attach the injection pump to bracket C.

Injection pump

Bracket C

P-VRZR- 309

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

TCV harness connector

Bracket bolts P-VRZR- 310

- 19 -

DISASSEMBLY Grommet

[2] Magnet valve removal

Nut

Magnet valve

(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

[3] GE actuator removal

GE cover

(1) Remove the GE actuator’s torx bolts and spring washers.

Torx bolts (6) Spring washers (6)

Tool name Bit

Part no

Holder

157915-9820

Bit

157915-9600

Remarks

T30

Advice Do not remove the GE cover. P-VRZR- 021

(2) Remove the GE actuator. Advice Do not damage the ball pin (refer to the GE actuator on page 35).

GE actuator

P-VRZR- 022

[4] Regulating valve removal Regulating valve

Assemble the socket wrench to the regulating valve and then remove the regulating valve.

Socket wrench

Tool name Socket wrench

P-VRZR- 023

- 20 -

Part no 157913-7000

Remarks

DISASSEMBLY [5] TCV (timing control valve) removal

Holder

(1) Remove the TCV’s torx bolts.

Bit

Tool name TCV torx bolts (2)

Part no

Holder

157915-9820

Bit

157915-9600

Remarks

T30

P-VRZR- 024

TCV

Screwdriver

Pump housing

(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.

P-VRZR- 025

[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

EEPROM

(1) Remove the EEPROM.

P-VRZR- 311

- 21 -

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

P-VRZR- 026

(3) Remove the TPS, the adjusting shim, the timer spring, the core rod and the TPS standard point shim. Advice Label the TPS standard point shim and the timer stroke adjusting shim to avoid mistaking them at reassembly.

Timer spring Adjusting shim TPS

TPS standard point shim

O-ring (large)

Core rod

P-VRZR- 027

(4) Remove the timer cover and the O-rings (large and small).

Torx bolts (2)

Tool name

Timer cover

O-ring (small)

Bit

Holder

P-VRZR- 028

- 22 -

Part no

Holder

157915-9820

Bit

157915-9600

Remarks

T30

DISASSEMBLY [7] CPV (constant pressure valve) holder and plug removal (1) Loosen the CPV holders. Tool name

Socket wrench

Socket wrench

Part no

Remarks

157914-3600

CPV holders (4)

P-VRZR- 029

(2) Remove the CPV holders and the gaskets. Advice Line up the removed CPV holders in order to match the positions (A, B, C, D) on the distributor head from where they were removed.

Gaskets (4) Distributor head CPV holders (4)

P-VRZR- 030

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

P-VRZR- 031

(4) Remove the snapring and shim from the rotor shaft. Note: The shim is easier to remove after removing the distributor head assembly.

Snapring Distributor head Shim

P-VRZR- 032

- 23 -

DISASSEMBLY [8] Distributor head removal (1) Remove the distributor head’s torx bolts.

Holder

Tool name

Bit Distributor head’s torx bolts (4)

Part no

Holder

157915-9820

Bit

157915-9600

Remarks

T30

Advice If the distributor head is not loose, tap the sides lightly with a plastic hammer. P-VRZR- 033

(2) Pull out the distributor head. Advice Do not drop the control sleeve. (3) Remove the washer.

Distributor head

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

Part no

Holder

157915-9820

Bit

157915-9301

Remarks

T20

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

- 24 -

DISASSEMBLY

Rotor shaft assembly

Rollers

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

P-VRZR- 036

Clip

Part no

Remarks

157971-0500

Advice Do not disassemble the plunger from the rotor shaft.

[10] Snapring removal Insert the hook’s pin into the snapring’s hole and tighten the butterfly nut to pull out the snapring.

Hook Pin Snapring

Tool name Hook

Part no

Remarks

157928-5820

P-VRZR- 037

[11] Drive shaft removal Remove the drive shaft, the washer and the seal ring.

Drive shaft

Seal ring Washer P-VRZR- 038

- 25 -

DISASSEMBLY [12] Cam ring removal

Cam ring

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

P-VRZR- 039

[13] Timer piston removal

Slot

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.

Slider

Timer piston

EEPROM installation position

P-VRZR- 040

[14] Bearing removal Insert the holder into the bearing, push the holder button and remove the bearing.

Button Holder

Tool name Bearing

Holder

P-VRZR- 041

- 26 -

Part no 157928-3620

Remarks

DISASSEMBLY [15] Feed pump removal

Short torx bolt Holder

(1) Remove the feed pump’s torx bolts.

Feed pump cover

Tool name

Bit Pump housing

Long torx bolts (3)

P-VRZR- 042

Part no

Holder

157915-9820

Bit

157915-9201

Remarks

T15

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 pump’s pump housing. For feed pump

Part no

Remarks

Short torx bolt

149916-0400 (9 443 612 874)

1

Long torx bolt

149916-0300 (9 443 612 873)

3

(2) Remove the feed pump cover. (3) Remove the feed pump O-ring.

(4) Position the feed pump holder chamfer toward the GE actuator. (5) Push the feed pump holder into the pump housing, aligning the holder’s two pins with the feed pump holes.

Feed pump holder Chamfer Pump housing

Tool name

Pins

Feed pump holder

Part no

Remarks

157928-4320

Feed pump

P-VRZR- 043

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

Pump housing

Bracket C

P-VRZR- 044

- 27 -

DISASSEMBLY (7) Hold the feed pump holder and turn the pump housing upside down. (8) Remove the feed pump holder with the feed pump from the bottom of the pump housing. Advice Remove the rotor assembly and the feed pump cover together with the feed pump holder.

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 Plate

Cover Feed pump

Part no

Remarks

157928-4800

Advice Always store the feed pump in the assembled state.

Holder

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 16 15

14

1 14 8

4

18

5

7

6 2

9 3

13 11 12

P-VRZR- 047

Repair kit part no: 149960-0020 (Bosch part no. 9 443 612 894) Key no

RBAJ part no

Bosch part no

Part name

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

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

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

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

- 29 -

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

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

(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.

Pump housing

Timer piston cylinder

Tool name

P-VRZR- 049

Service kit

Part no

Remarks

149500-0420 (9 443 613 486)

[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 Oil seal

Part no

Remarks

Collet

157928-4100 For φ 25 shaft dia

Extractor

157928-4120 For φ 25 shaft dia

Note: The collet, bar and pushrod (see next page) are part of the extractor. Collet P-VRZR- 051

- 30 -

COMPONENT INSPECTION (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.

Press Bar

Pushrod

Tool name

Oil seal

Part no

Remarks

Bar

157925-2800 For φ 25 dia shaft

Pushrod

157926-1000

Collet

P-VRZR- 052

[4] Oil seal installation

Press Outer surface

(1) Apply wax sealant (L101; manufactured by NOK) to the outside surface of a new oil seal.

Pump housing

Tool name Guide

Oil seal

P-VRZR- 053

Part no

Remarks

157848-2300

(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

Drive shaft assembly P-VRZR- 055

(1) Replace the drive shaft assembly if the drive key or the feed pump’s 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.

- 31 -

COMPONENT INSPECTION (6) Replace the drive shaft assembly if there is any play between the rotor shaft’s ball pin and the drive shaft. Ball pin

Drive shaft assembly

Rotor shaft

P-VRZR- 056

[7] Rotor shaft assembly Rotor shaft assembly

(1) Replace the distributor head assembly if any of the rotor shaft assembly’s sliding parts are peeling, gnawed or scorched. (2) Replace the washer with a new one if it is worn.

Radial plungers

Roller shoes Washer

Rollers

P-VRZR- 057

[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 timer slider.

Cam ring

Pin

Timer slider

P-VRZR- 058

(3) Replace the cam ring if the cam ring’s cam profile is peeling or scorched. Cam ring

P-VRZR- 059

- 32 -

COMPONENT INSPECTION [9] Timer piston (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.

Timer piston

Slider

Tool name Service kit P-VRZR- 060

Part no

Remarks

149500-0420 (9 443 613 486)

[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

(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.

Radial plungers

Roller shoes Rollers

P-VRZR- 062

(4) Replace the distributor head assembly if there is any play between the cam ring’s plate and the link’s pin.

Link’s 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 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.

Regulating valve

O-rings

Stopper

P-VRZR- 067

- 34 -

COMPONENT INSPECTION [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. 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.

Magnet valve

O-ring Spring Armature Gauze filter

Terminal nos 1 - GND

P-VRZR- 068

GE actuator

Ball pin

Resistance (Ω ) 8.0±1.2

Ambient temperature (°C) 23±5

(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

(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.

GE actuator

Control sleeve

GE actuator terminals (reference) P-VRZR- 070

6 5 4

12 11 10

3 2 1

9 8 7

P-VRZR- 312

- 35 -

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

COMPONENT INSPECTION (3) Measure the resistances between each of the terminals. Reference values:

6 5 4

12 11 10

3 2 1

9 8 7

Terminal nos 6 - 10 8 - 12 4-8 4 - 12 7 - 11

Resistance (Ω ) 0.71±0.25 5.9±0.3 5.9±0.3 11.8±0.6 2.0±0.6k

Ambient temperature (°C) 23±5 23±5 23±5 23±5 23±5

P-VRZR- 313

[16] TCV (timing control valve) (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.

TCV

Filter P-VRZR- 073

(3) Measure TCV resistance. Reference values: Terminal nos 5-9

Resistance (Ω ) 11.0±0.8

Ambient temperature (°C) 23±5

TCV

P-VRZR- 074

[17] TPS (timer piston sensor) TPS

(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:

Timer spring

4

1

5

2 6

3 Core rod P-VRZR- 075

- 36 -

Terminal nos 1-3 2-3

Resistance (Ω ) 82.0±5.7 82.0±5.7

Ambient temperature (°C) 25±10 25±10

COMPONENT INSPECTION [18] Np sensors

Np sensors

Measure the Np sensors’ resistances.

1

Terminal nos 2-3 2-3

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

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.

[19] Fuel temperature sensor

(kΩ)

Resistance

Resistance (Ω ) Remarks 2.15k Main 2.15k Backup

Measure fuel temperature sensor resistances. See page 35 for GE actuator terminals. Reference values: Terminal nos 7-8

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

Fuel temperature (°C)

P-VRZR- 163

- 37 -

Resistance (Ω) 2

Fuel temperature (°C) 25

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. 1/8

1/6

1/5

1/3 1/2 1/4

3

2

1/1 P-VRZR- 327

Key no

RBAJ part no

Bosch part no

1/1

149931-1910

9 443 613 479

Main gear

1

1/2

149931-2000

9 443 613 480

Sub-gear

1

1/3

149931-1600

9 443 613 481

Snapring

1

1/4

149931-1200

9 443 613 482

Spring

1

1/5

149931-1300

9 443 613 483

Pin

2

1/6

149931-1400

9 443 613 484

Pin

1

1/8

149917-1500

9 443 613 485

Socket head bolt

1

2

149931-0600

9 443 612 889

Pulse plate

1

3

149917-1400

9 443 612 878

Bolt

4

Part name

Qty

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

Pin

Part name

Main gear

Pin

P-VRZR- 328

- 38 -

Part no Remarks (Mitsubishi part no)

Pin

149931-1300 (ME204193)

Main gear

149931-1910 (ME204369X)

GEAR REASSEMBLY (2) Fully pressfit the pin to the sub-gear. Advice Pressfit the pin to the face of the gear without the mark ‘A.’

Pin

Sub-gear

Pin

Part name

Base

Pin

149931-1300 (ME204193)

Sub-gear

149931-2000 (ME204370)

P-VRZR- 329

Back is stamped ‘A’

Racks (2)

Part no Remarks (Mitsubishi part no)

(3) Fix the base in a vise. (4) Install the racks to the base using the socket head bolts.

Socket head bolts (2)

Tool name

Part no

Remarks

Base

The racks are 157924-8520 included with the base.

Rack

Use the racks with 157917-4300 the '4M41' stamping.

Hexagon wrench (SW5)

P-VRZR- 330

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

Main gear Base

P-VRZR- 331

(6) Align the spring with the main gear’s pin. Part name

Main gear Spring

Spring Pin

P-VRZR- 332

- 39 -

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

GEAR REASSEMBLY (7) Attach the sub-gear to the main gear. At this time, hook the sub-gear’s pin to the spring.

Sub-gear

Spring Pin

P-VRZR- 333

(8) Align the wrench with the sub-gear’s holes and attach it to the sub-gear.

Wrench

Tool name Sub-gear

Wrench

Part no

Remarks

157917-4920

P-VRZR- 334

(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 N·m {0.9 ~ 1.3 kgf·m}

Socket head bolt Wrench

Sub-gear

Part name Socket head bolt P-VRZR- 335

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

SW5

CAUTION Pliers

Snapring

Socket head bolts cannot be reused.

Main gear

(11) Hold the snapring open using pliers and install it in the main gear’s snapring groove. Tool name Pliers Part name Snapring

Base P-VRZR- 336

- 40 -

Part no

Remarks

157928-4400 Part no Remarks (Mitsubishi part no) 149931-1600 (ME204236)

GEAR REASSEMBLY

Sub-gear Pin Drive gear assembly

(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

Part no Remarks (Mitsubishi part no) 149931-1400 (MF472404)

Pin

P-VRZR- 337

(13) Turn the drive gear assembly upside down, align it with the racks and attach it to the center of the base.

Drive gear assembly

Base

P-VRZR- 338

(14) Align the pulse plate’s long hole with the drive gear’s positioning pin and attach it to the drive gear.

Long pulse plate hole Pulse plate Positioning pin

Part name Pulse plate

Base

Part no Remarks (Mitsubishi part no) 149931-0600 (ME203076)

P-VRZR- 339

(15) Screw in the bolts (SW7) and tighten the pulse plate to the drive gear. Specified torque: 4 ~ 5 N·m {0.4 ~ 0.5 kgf·m}

Bolts (4) Pulse plate Drive gear

Part name Bolts

Part no (Mitsubishi part no)

Remarks

149917-1400 (MF472404)

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

Pins

Advice • Confirm that the blades’ grooves are positioned toward the inside. • Blade and rotor orientation cannot be changed. • The feed pump’s 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.

(1) Position the feed pump assembly and the cover on the feed pump holder. Assemble the holder pins in the feed pump holes (2).

Cover

Tool name Notch

Feed pump holder

Chamfer

Notch

Feed pump holder

Part no

Remarks

157928-4320

Advice Align the feed pump cover notch with the feed pump holder chamfer.

Feed pump P-VRZR- 078

(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.

Notch

Pump housing

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

(5) Screw the set screw into the pump housing. (The set screw is used as a guide when positioning the feed pump cover.)

Set screw

Tool name Set screw

Part no

Remarks

157928-4500

(6) Assemble the feed pump O-ring to the feed pump. (Refer to page 29 for the O-ring key number.)

Feed pump

P-VRZR- 081

(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.

Guide

Set screw

Tool name Guide

Part no

Remarks

157928-4200

(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 N·m {0.3 ~ 0.4 kgf·m}

Holder Bit

For feed pump

Part no

Remarks

Short torx bolt

149916-0400 (9 443 612 874)

1

Long torx bolt

149916-0300 (9 443 612 873)

3

P-VRZR- 083

Tool name

Part no

Remarks

Holder

157915-9820

Bit

157915-9201 T15

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.

Seal ring

Feed pump side

Head side

P-VRZR- 084

[2] Bearing reassembly Button

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

Holder Bearing

Tool name

Pump housing

Holder

Part no

Remarks

157928-3620

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

Timer’s low pressure side

Pump housing

Slider hole

Timer piston

Timer’s low pressure side P-VRZR- 087

(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

Cam ring

Assemble the cam ring in the pump housing. At this time, insert the cam ring pin into the timer piston’s 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

Holder

Part no

Remarks

157928-3620

P-VRZR- 089

Spacer

Feed pump cover

(3) Insert the spacer into the pump housing.

Spacer

Tool name Spacer

Part no

Remarks

157928-4700

U-shaped ring

Bearing

Pump housing

P-VRZR- 090

(4) Assemble the shim and the feed pump’s drive side key on the drive shaft. (5) Assemble the oil seal guide on the drive shaft thread.

Shim Key

Drive shaft

Tool name

Part no

Oil seal guide

157928-4000

Remarks For φ 25 dia shaft

Oil seal guide P-VRZR- 091

(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.

Drive shaft

P-VRZR- 092

- 46 -

REASSEMBLY Plastic hammer

;;

Drive shaft

1 ~ 2 mm

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.

[6] Snapring reassembly

Spacer

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

Pump housing

P-VRZR- 094

(2) Assemble the snapring to the clip. Tool name Clip

Part no

Remarks

157928-3120

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

Clip Snapring

Convex face

P-VRZR- 095

(3) Position the snapring in the drive shaft’s 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.

Clip Drive shaft’s snapring groove

Snapring

P-VRZR- 096

- 47 -

REASSEMBLY [7] Adjusting drive shaft axial play

Distributor head

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

Pump housing

P-VRZR- 097

(2) Install and tighten two diametrically opposed torx bolts of the four to install the distributor head. Specified torque: 10.0 ~ 14.0 N·m {1.0 ~ 1.4 kgf·m}

Holder

Bit

Tool name

Torx bolts (2)

Part no

Remarks

Holder

157915-9820

Bit

157915-9600

T30

P-VRZR- 098

(3) Attach the measuring device to the drive shaft. (4) Attach the dial gauge to the measuring device.

Measuring device Dial gauge

Tool name Measuring device

Drive shaft

Remarks

105782-4530

P-VRZR- 099

Measuring device

Drive shaft

Part no

P-VRZR- 100

(5) Measure the drive shaft’s axial play. Specified value: 0.1±0.05 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

Bosch part no

Thickness (mm)

149602-0000 149602-0100 149602-0200 149602-0300 149602-0400 149602-0500 149602-0600 149602-0700 149602-0800 149602-0900 149602-1000

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

1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40

(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.

Measuring device

Tool name Extractor

Extractor

Part no

Remarks

157926-2421

P-VRZR- 101

(10) Remove the torx bolts from the distributor head. (11) Remove the distributor head from the pump housing.

Distributor head

Pump housing

P-VRZR- 102

[8] Selecting the rotor shaft shim

Rotor shaft

Purpose The rotor shaft’s axial play is measured and then the play is adjusted to the specified value using the shim.

Distributor head

Procedure 1

Snapring P-VRZR- 103

Adjusting the dial gauge’s ‘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.

- 49 -

REASSEMBLY (3) Attach the adapter to the head and then attach the measuring device to the adapter.

Head

Tool name Measuring device

Rotor shaft

Part no

Adapter

157845-8900

Measuring device

157829-3520

Remarks

For measuring VE cam lift

Adapter P-VRZR- 104

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

Head

Measuring device

Rotor shaft Adapter

Dial gauge P-VRZR- 105

Procedure 2

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 shaft’s groove must not catch on the head.

Head

Measuring device

Adapter

Rotor shaft

P-VRZR- 106

(2) Select a shim using the formula below. Shim thickness = full stroke – 0.2 (mm)

Rotor shaft Distributor head

Shim

Snapring P-VRZR- 107

RBAJ part no (key no. 53)

Bosch part no

Thickness (mm)

149720-0000 149720-0100 149720-0200 149720-0300

9 443 612 851 9 443 612 852 9 443 612 853 9 443 612 854

2.1 2.2 2.3 2.4

(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: 0.2±0.1 mm

- 50 -

REASSEMBLY (5) Remove the dial gauge and adapter from the head. (6) Remove the snapring.

[9] TPS and timer cover reassembly

TPS standard point shim

Pump housing

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

Adjusting shim Core rod

TPS

P-VRZR- 108

(2) Assemble the O-rings (at two locations) and then assemble the high pressure side timer cover on the pump housing. Specified torque: 7.0 ~ 10.0 N·m {0.7 ~ 1.0 kgf·m}

Pump housing Timer cover

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

Cam lift (mm)

Pre-stroke adjustment values

Control sleeve

Original pre-stroke

Timing link shaft ball pin

Angle of cam rotation (°)

Beginning of cam lift

Cam link pin

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 cam’s 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 device’s measuring terminal with the standard cylinder B’s cam position. (3) Find the cam’s 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 [1] Measuring device installation

Flange

Injection pump

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

Part no

Remarks

Fixing stand

105796-0000 For 20NP

Flange

157811-9020 For VRZ

(2) Align the key groove with the standard cylinder B’s 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

Measuring device

Existing bolts (2)

(3) Align the drive shaft key groove and the measuring device’s 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 device’s 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 N·m {1.0 ~ 1.4 kgf·m}

Drive shaft

Tool name Measuring device

Assembly position of measuring device’s measuring terminal P-VRZR- 112

Part no

Remarks

105782-4540

Advice • Align the drive shaft’s key groove and the measuring device’s 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.

Coupling Fixing stand

Tool name Coupling

Specified torque:

Part no

Remarks

157847-0820 Shaft dia φ 25

167 ~ 185 N·m {17.0 ~ 19.0 kgf·m}

P-VRZR- 114

(6) Move the fixing stand to assemble the coupling teeth to the pump test bench drive coupling. Advice Ensure approximately 1 mm axial clearance between the coupling and the drive coupling.

Test bench drive coupling

Fixing stand

P-VRZR- 115

(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.

Flywheel

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

Monitor display example angle measurement

1

2

3

4

5

6

7

8

9

10

11

12

(1) Turn the pump test bench’s 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’

F1

F2

F3

F4

F5

F6

F7

Press F6 Select ‘Settings’ Press ‘Enter’ Set the direction of rotation Press F2 F2

F8

P-VRZR- 164

(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.)

Flywheel

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

1

5

3

6

2

4

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.

P-VRZR- 119

(9) Remove the measuring device.

Measuring device

P-VRZR- 120

- 56 -

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

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 Replaced

Replaced

Replaced

Replaced

Not replaced

Replaced

Not replaced

Replaced

Replaced

Not replaced

Not replaced

Do not replace (use the installed forked plate)*

Forked plate

Holder

Bit

Forked plate marked G

P-VRZR- 122

Drive shaft Spring

Clip

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 N·m {0.3 ~ 0.5 kgf·m} Tool name

Rotor shaft

Rotor shaft assembly

P-VRZR- 123

Part no

Remarks

Holder

157915-9820

Bit

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

Remarks

157971-0500

(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 N·m {1.0 ~ 1.4 kgf·m}

Torx bolts (4)

Tool name

Holder

Bit

Part no

Holder

157915-9820

Bit

157915-9600

Remarks

T30

P-VRZR- 127

(10) Assemble the shim and snapring to the rotor shaft. (11) Install the plug to the distributor head together with a new O-ring.

Snapring O-ring

Shim Plug P-VRZR- 128

(12) Tighten the plug using a hexagon wrench (SW14mm). Specified torque: 20.0 ~ 29.0 N·m {2.0 ~ 3.0 kgf·m}

Plug Hexagon wrench

P-VRZR- 129

(3) CPV holder reassembly (1) Assemble the gaskets and CPV holders to the distributor head’s 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 head’s cylinder B.

Dummy holder Cylinder B

Gaskets (4) CPV holders (3)

Tool name Distributor head

P-VRZR- 130

- 59 -

Holder

Part no 157845-9500

Remarks Part of pipe assembly 157845-9520.

REASSEMBLY (3) Tighten the CPV holders using a socket wrench. Specified torque: 44.0 ~ 54.0 N·m {4.5 ~ 5.5 kgf·m}

CPV holder

Socket wrench

Tool name Socket wrench

Part no

Remarks

157914-3600

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

(3) Push the TCV into the pump housing using your finger and fix it using the torx bolts. Specified torque: 7 ~ 10.0 N·m {0.7 ~ 1.0 kgf·m}

Pump housing

Tool name

TCV

Holder

Bit

Torx bolts (2)

P-VRZR- 134

- 60 -

Part no

Holder

157915-9820

Bit

157915-9600

Remarks

T30

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

Ti m e r cover Large O-ring

P-VRZR- 135

Pump housing Large O-ring

Small O-ring

Ti m e r cover

Torx bolts (2)

(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 N·m {0.7 ~ 1.0 kgf·m} Tool name

Bit Holder

Part no

Holder

157915-9820

Bit

157915-9600

Remarks

T30

P-VRZR- 136

TPS

(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.

O-ring

Timer stroke adjusting shim

Timer spring Core rod Standard point shim

Pump housing

P-VRZR- 137

(6) Secure the TPS to the pump housing using the torx bolts and a socket wrench (M6). Specified torque: 7.0 ~ 10.0 N·m {0.7 ~ 1.0 kgf·m}

Pump housing TPS

Socket wrench Torx bolts (2) P-VRZR- 138

- 61 -

REASSEMBLY (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.

Regulating valve Pump housing

P-VRZR- 139

(3) Tighten the regulating valve using the socket wrench. Specified torque: 10.0 ~ 13.0 N·m {1.0 ~ 1.3 kgf·m}

Socket wrench

Tool name Socket wrench

Part no

Remarks

157913-7000

P-VRZR- 140

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

GE actuator Seal ring

P-VRZR- 141

(2) Position the control sleeve groove toward the GE actuator and fix it in an intermediate position. Note: This facilitates GE actuator installation.

Control sleeve groove

Rotor shaft P-VRZR- 142

- 62 -

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

GE actuator pin

P-VRZR- 143

GE actuator

P-VRZR- 144

(4) Move the GE actuator in an axial direction as shown by the arrow in the figure at left and confirm that the actuator moves smoothly. Advice • Do not force the GE actuator. Forcing it may damage the seal ring. • The GE actuator will not move if its pin is not inserted into the control sleeve groove. If it will not move, remove the GE actuator and again insert the pin into the groove. (5) Move the GE actuator fully toward the full side (ie, the head side). Advice If the GE actuator is positioned toward the drive shaft side, it may not be possible to measure the pre-stroke.

GE actuator

P-VRZR- 145

Holder

(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 N·m {0.7 ~ 1.0 kgf·m}

Torx bolts (6)

Bit

Tool name Pump housing

P-VRZR- 146

- 63 -

Part no

Holder

157915-9820

Bit

157915-9600

Remarks

T30

REASSEMBLY (8) Magnet valve assembly installation (1) Install the magnet valve assembly to the GE actuator. Advice Ensure the filter is installed securely.

Magnet valve assembly GE actuator Magnet valve O-ring Spring

Armature Gauze filter P-VRZR- 147

(2) Tighten the magnet valve assembly using a torque spanner. Specified torque: 20.0 ~ 25.0 N·m {2.0 ~ 2.5 kgf·m}

Magnet valve assembly Spanner

P-VRZR- 148

(9) Pre-stroke adjustment (1) Connect the fuel hose to the injection pump using the adapter.

Gaskets (2)

Tool name

Adapter Injection pump

Part no

Adapter

157977-8000

Gasket

026512-1640

Remarks

Hose P-VRZR- 149

(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.

Plugs

P-VRZR- 150

- 64 -

REASSEMBLY (3) Remove cylinder B’s delivery valve holder and assemble the pipe assembly to cylinder B.

Pipe assembly

Tool name Cylinder B

Pipe assembly

Part no

Remarks

157845-9520

P-VRZR- 151

(4) Connect the direct current harness to the magnet valve. Advice Magnet valve supply voltage • 12V specification: 12V

Magnet valve assembly Direct current harness

P-VRZR- 152

(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.

Injection pump

P-VRZR- 153

(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.

Flywheel

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 assembly’s overflow. • Align the flywheel with the position set during Procedure [2] ‘‘Setting the ‘0’ point for pre-stroke adjustment ’’ on page 55.

Pipe assembly

P-VRZR- 155

(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.

Pipe assembly

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.

Cam ring

Forked plate

P-VRZR- 157

(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: 2.5±0.5° 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.

- 66 -

REASSEMBLY Forked plates for 4 cylinders 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

(11) Remove the pipe assembly from cylinder B and replace it with the CPV holder. Replace the gasket at the same time.

CPV holder

Cylinder B

P-VRZR- 158

(12) Tighten the CPV holder using a socket wrench. Specified torque: 44.0 ~ 54.0 N·m {4.5 ~ 5.5 kgf·m}

Plugs

Tool name

Part no

Socket wrench

157914-3600

(13) Remove the plugs.

CPV holder

Socket wrench

P-VRZR- 159

- 67 -

Remarks

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 OS

Windows 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 devices

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

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 Tubes

Nozzle and nozzle holder assembly (1 688 901 035)

Cooling unit

Injection tubes

Joint assembly (157641-6820)

Injection pipes (157808-4720)

- 68 -

P-VRZR- 390

ADJUSTMENT (2) Fuel piping Key no

RBAJ part no

Bosch part no

Part name

Qty

Remarks

1

157971-1020

9 443 613 442 Piping assembly

-

For VRZ overflow fuel piping

1/1

157971-1100

9 443 613 443 Bolt

1

For distributor head overflow

1/2

026512-1640

9 421 617 041 Gasket

6

For distributor head overflow

1/3

029711-2180

9 442 610 444 Eye

2

For distributor head overflow

1/4

157971-1000

9 443 613 444 Adapter

1

For distributor head overflow

1/5

017211-2010

9 442 611 983 Hose clip

2

For distributor head overflow

1/6

157986-8100

9 443 613 445 Hose

1

For distributor head overflow

1/7

026510-1340

9 442 610 043 Gasket

1

For distributor head overflow

Piping outline

Pressure gauge

Overflow measurement hose

1/4

1/5 1/1

1/3 1/6

1/2

Multi-way cock

1/2 1/5

1/7 Test oil hose

Pump chamber pressure measurement hose

Temperature sensor cable

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) Intermediate harness (157966-2421)

Personal computer

Intermediate harness (157966-5720)

Dsub 9 pin

FCV GND harness (157966-4820)

Dsub 25 pin

Dsub 7 pin ROM harness (157966-5020) Dsub 9 pin To AC100V - AC120V or AC200V - 240V power source (157966-4420 or 157966-4520)

Main harness (157966-4920)

VRZ and COVEC-F controller unit

Earth to injection pump or pump test bench P-VRZR- 392

(2) Wiring connections inside controller unit

PC

VRZ & COVEC-F (ROM) CONTROLLER AC 100 - 120V 200 - 240V

COM2

COM1

RS232C COM2 25 pin

RS232C COM2 9 pin

ROM cable

ROM writer

ROM

ROM lamp AC socket

ECU lamp DC 5V Constant power supply

4D56 (COVEC-F) ECU

FCV switch Main power switch

Main cable

FCV line

DC 24V Constant power supply

ECU lamp

DC 12V Constant power supply

FCV switch

Power lamp

0

1

FCV switch

2

Sub-switch

3 Selector switch

4M41 (VRZ) ECU

Main cable FCV line FCV line

ECU lamp

Injection pump

GE CSP TPS TCV TF FCV

Main cable

WL (COVEC-F) ECU

4

P-VRZR- 395

- 70 -

ADJUSTMENT [4] Related materials No.

Publication No.

Remarks

1

ED14E-11021

When installing the ECU assembly for the controller unit, refer to the installation instructions included with the controller unit.

2

ED14E-11011

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 8

7

4

1

5

2

11

9

6

13

3

10

12

14 P-VRZR- 344

Key no

Name

Use and purpose

1

Pump side wire harness connection

For connecting harness for injection pump's harness connectors and GE controller.

2

Pump side wire harness connection

For connecting harness for injection pump's harness connectors and GE controller.

3

Pump side wire harness connection

For connecting harness for injection pump's harness connectors and GE controller.

4

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).

5

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).

6

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).

7

4D56 ECU pilot lamp

Orange lamp lights when 4D56 ECU in use.

8

4M41 ECU pilot lamp

Orange lamp lights when 4M41 ECU in use.

9

WL ECU pilot lamp

Orange lamp lights when WL ECU in use.

10 Power pilot lamp

Orange lamp lights when ECU in use (when breaker is turned ON).

- 72 -

ADJUSTMENT Key no

Name

Use and purpose

11 ECU changeover switch

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

12 Sub-switch

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.

13 ROM pilot lamp

Green lamp lights when ROM in use.

14

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

3

4

2

CE

1

P-VRZR- 345

Key no

Name

Use and purpose

1

AC100V - 120V power or AC 200V - 240V power terminal

Connect to AC100V - 120V, 50/60Hz power source or AC 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.

3

D-sub 9 pin cable connection (COM1)

Connects RS232C cable to personal computer (for GE).

4

D-sub 25 pin cable connection (COM2)

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 -

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]

[4]

Part no. input [1] Adjustment [2] Inspection

[5]

Manual operation

- 75 -

Pre-check 1.

Adjustment Step 1-XX Adjustment

Exit

Input item [1] Workshop name [2] Address [3] Telephone [4] Fax [5] Operator's name [6] Password

Confirmation

Program completed

Select "Registration" button

StepXX + 2 ROM writing

Confirmation

Repeat measurement Adjustment result

Repeat measurement Inspection result OK

Print result

P-VRZR- 396

Final confirmation

OK

Cancel

Push [MENU] button (= Registration change completed)

Cancel Push [MENU] button (= Item is not changed)

ADJUSTMENT

Cancel

OK Final confirmation

Workshop name registration

Inspection Step 1-XX Inspection

StepXX + 1 ROM compensation

Print result

[6]

3. PUMP ADJUSTMENT TOOL FLOW CHART

1. Password input

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

1

ROM COVEC-F MITSUBISHI 12V Inspection/adjustment

2

VRZ MITSUBISHI 12V Inspection/adjustment

3

ROM COVEC-F MAZDA 12V Inspection/adjustment

4

Manual operation

5

Workshop name registration

6

Exit

RBAJ

P-VRZR- 346

No.

Name

Use and purpose

1

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

2

4M41 model engine's VRZ type injection pump inspection / adjustment key

3

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

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

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

- 76 -

ADJUSTMENT 5. PUMP ADJUSTMENT TOOL MONITOR SCREEN OUTLINE Inspection and adjustment step screen Pump adjustment tools for service

Pump information

1 2 3

N

0 r/min

T

0.0 deg C

44-6666 44-3032 000000000b 00000-000-0000b

V

Right 4 cylinders

6 7

ECU

3

Q

5

0.000 MPa

Qo

0.0 l/h

20

MELCO

Mode Pump type

0.0 mm /st

Pt

19

VRZ 4M41 Rotation

Ua-ist

4

Only items necessary for each step are displayed.

Inspection and adjustment steps monitor screen

Input part no.

Adjustment VRZ(12V)

21

2001-01-15 11:28:44

TF

V

8

VTPS

V

9

TPS

V

10

TA

11

MENU

Part number input

22 17 16

mm 0.0 mm3/st

DQ

23 Circled numbers indicate fields where input is necessary.

24

12

Zero set

13 Back

Next

No. 1

Soll-cor Step information

18 14 15

No.

STEP

03 P_cham_ADJ

Step status Comment

N

Soll

Soll-cor

TCVF

DTCV

1000rpm

2.91v

0.00mv

60Hz

100%

500rpm

2.50v

60Hz

0%

PT standard point

25

Next Sequence

03 / 32

Select

04

After values are input, push 'Next' button.

Name Pump speed input

P-VRZR- 347

Use and purpose

N: pump speed

Input the pump's speed.

2

Test oil temperature input

3

Actual control sleeve position voltage display

U α soll: 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

11 Variation between cylinders display

T: test oil temperature

Input the test oil temperature. Displays actual control sleeve position voltage.

TA: timer stroke

Displays TA (timer stroke) output.

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 (

16 Menu key

To set at MENU display.

BACK,

NEXT).

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 items are within specifications.

19 Part number, serial number display

Displays pump information part number (specification, pump) and serial number (pump, GE).

20

Displays pump information specifications.

Specification display

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 of specifications.

24

Current step display

Displays current step items.

25

Next step display

Displays next step's items.

- 77 -

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

Pump adjustment tools for service MC-02 TESTER

Manual operation ECU reader data Item

1

Value

Unit

GE Vist Item

Item

Value

Item

Unit

TF

Value

TPS Vist

V

V Value

Np

deg C

Unit

Unit

r/min

Select ECU

5

ROM COVEC-F MITSUBISHI 12V

VRZ MITSUBISHI 12V

ROM COVEC-F MAZDA 12V

ECU configuration data Input

2

GE Soll GE Soll-cor

V mV

TCV Duty

%

TCV Frequency

Hz

3

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

Initialize ECU

4

Menu

P-VRZR- 348

No.

Name

Remarks

1

Control sleeve position actual voltage display

Displays actual control sleeve position voltage.

2

Control sleeve position target voltage display

By operating the input keys, the control sleeve position can be set for 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.

- 78 -

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

Pump adjustment tools for service

MC-02 TESTER

Workshop name registration

1 2 3 4 5 6

Workshop name Address

RBAJ JAPAN

Telephone

000-000-0000

Fax

111-111-1111

Operator's name

sse

Password

****

Input items and select Registration button.

7

Menu

Registration

8 P-VRZR- 350

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.

WORKSHOP REGISTRATION (1) Select ‘Workshop name registration.’

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

Manual operation

(1) Workshop name registration

Exit

P-VRZR- 346

(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.)

MC-02 TESTER

Workshop name registration

Workshop name Address

RBAJ JAPAN

Telephone

000-000-0000

Fax

111-111-1111

Operator's name

sse

Password

****

(2)

Input items and select Registration button.

(3) Menu

Registration

P-VRZR- 350

- 79 -

ADJUSTMENT 8. ADJUSTMENT Adjustment sequence Recording the pump and GE serial numbers

Preparation

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Part no. input and installation confirmation Warming-up operation

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Injection quantity compensation point adjustment Compensation ROM interpolation calculation Writing to the compensation ROM

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Magnet valve operation confirmation Second timing adjustment

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Timer stroke and characteristic confirmation Non-injection confirmation

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Pump chamber pressure confirmation

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Standard injection quantity point adjustment

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Pump chamber pressure adjustment

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Pre-stroke adjustment

TPS zero setting

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Finish

- 80 -

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See page 81 [2], 82 [3] See page 83 [4] See page 84 [5]

See page 64 (9) See page 85 [6] See page 86 [7] See page 86 [8] See page 87 [9]

See page 88 [10] See page 88 [11] See page 89 [12] See page 89 [13]

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See page 90 [15]

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See page 94 (4)

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See page 81 [1]

See page 90 [14]

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 pump’s 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’s serial number. Advice It is easier to read the GE actuator’s 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

Test oil hose Injection system piping

P-VRZR- 353

ROM harness COM2

COM1

Controller unit Controller assembly harness for VRZ adjustment

P-VRZR- 354

(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 assembly’s wire harness and intermediate harness to the injection pump’s connectors. (Refer to page 70 for the controller assembly’s wiring.) (4) Connect the ROM controller’s wire harness and intermediate harness to the injection pump’s VRZ EEPROM connector. (5) Connect the FCV GND harness to the controller assembly’s 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.

- 81 -

ADJUSTMENT (8) Reconfirm that the coupling and the fixing stand bolts and nuts are securely tightened. (9) Set the 20NP pump test bench’s test oil outlet temperature at 45°C. (10) Set the cooling unit oil delivery pressure lever at ‘80 kPa {0.8 kgf/cm2}’ or less.

Fixing stand

P-VRZR- 355

(11) Connect the wire harness to the controller unit’s 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.

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

ECU for VRZ type injection pump No. 1 ~ No. 4 changeover switch P-VRZR- 397

[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

(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.

MC-02 TESTER

Precaution Password is required to actuate adjustment tools. Input password and press ENTER key.

(3)

P-VRZR- 357

- 82 -

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

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

Service tools for pump adjustment Version1.0

RBAJ

and

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

ROM COVEC-F MITSUBISHI 12V Inspection/adjustment

(1)

VRZ MITSUBISHI 12V Inspection/adjustment

input

ROM COVEC-F MAZDA 12V Inspection/adjustment

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)

446613

Pump serial no. (10 digits)

Pump part no. (last 6 digits)

443062

GE serial no. (13 digits)

System specifications Rotation Pump cylinders ECU

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

Adjustment

Mode

(4) (5)

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*

VRZ_4M41 Right 4 cylinders MELCO

Engine model

0880052496 5062008852056

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 GE’s serial number (13 digits) and press ‘Enter’. (6) Press the ‘Next’ key.

P-VRZR- 358

(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.

MC-02 TESTER

Setup confirmation Installation confirmation Click on appropriate item and explanatory illustration is displayed. 1. Injection system piping 2. Overflow piping

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

3. Adjustment controller wiring 3

4. Operation sequence

2

4

If necessary to proceed after confirmation, push Next button. 1

Menu Back

Next

P-VRZR- 359

- 83 -

ADJUSTMENT [5] Warming-up operation

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

Unit

Specification

Tolerance

Pump information Specified part no.

N

0 r/min

Pump part no.

44-3062

Pump serial no.

T

0.0 deg C

Ua-ist

V

(4)

50620-088-52056

Engine model

VRZ_4M41 Right

Rotation

0.0 mm3/st

0880052496

GE serial no.

Pump cylinders

Q

44-6613

4 cylinders

ECU

MELCO

Mode

Adjustment

Pump type

VRZ (12V)

05/04/03 13:20:52 Menu

Step information

(5) (6)

Step status

No.

Step name

Present step

01

Comment

Check for fuel leaks.

Warm-up

Part number input

N

Soll

Soll-cor

Frequency

300r/min

2.80v

0.00mv

60Hz

Duty 100%

1000r/min

2.91v

0.00mv

60Hz

100%

Next Sequence Select

01 / 31 02

After values are input, push Next button.

Warm-up

(2)

P-VRZR- 360

(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 α ist is displayed automatically. (10) Confirm injection. (11) Confirm that no fuel leaks from the injection pump fuel piping connections.

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

Unit

Specification

Tolerance

Pump information Specified part no.

N

0 r/min

T

0.0 deg C

Ua-ist

V

Pump part no.

(9)

50620-088-52056

Engine model

VRZ_4M41 Right

Rotation

0.0 mm3/st

0880052496

GE serial no.

Pump cylinders

Q

44-6613 44-3062

Pump serial no.

4 cylinders

ECU

MELCO

Mode

Adjustment

Pump type

VRZ (12V)

05/04/03 13:21:45 Menu

Step information

(13)

Step status

(14)

Next

No.

Step name

Present step

02

Comment

Warm-up

Sequence Select

Warm-up

02 / 31 03

Soll

Soll-cor

Frequency

1000r/min

2.91v

0.00mv

60Hz

Duty 100%

1000r/min

2.91v

0.00mv

60Hz

100%

After values are input, push Next button.

P-cham_ADJ

(7)

Part number input

N

(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 α ist is displayed automatically. (5) Confirm that the Step status field is green. (6) Proceed to the next step. Advice If U α 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 α ist values are as specified. Note: If not as specified after confirming U α ist several times, the GE may be faulty.

CAUTION

P-VRZR- 361

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

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

Unit

Specification

Tolerance

Pump information Specified part no.

N

0 r/min

T

0.0 deg C

Ua-ist

V

Pump part no.

44-3062

Pump serial no.

(3)

50620-088-52056

Engine model

VRZ_4M41 Right

Rotation

0.000 MPa

Qo

0.0 I/h

TF

0880052496

GE serial no.

Pump cylinders

Pt

44-6613

4 cylinders

ECU

MELCO

Mode

Adjustment

Pump type

VRZ (12V)

V 05/04/03 13:22:24 Menu

Step information

(7) (8)

Step status

No.

Step name P-cham_ADJ

Present step

03

Comment

PT standard point

Part number input

N

Soll

Soll-cor

Frequency

1000r/min

2.91v

0.00mv

60Hz

Duty 100%

1000r/min

2.91v

0.00mv

60Hz

100%

Next Sequence Select

03 / 31 04

After values are input, push Next button.

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 α 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

Holder Plug

•

Spring

Replace the regulating valve assembly and adjust the pump chamber pressure to the specified pressure.

When the pump chamber pressure is less than the specifications

Piston Stopper

pressure

•

Adjusting device

P-VRZR- 240

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

Part no

Adjusting device

157829-0820

Remarks

(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 [7] Standard injection quantity point adjustment

Service tools for pump adjustment Adjustment display

Status

Measured / input value

Item

Unit

Specification

Tolerance

Pump information 44-6613

Specified part no.

N

0 r/min

T

0.0 deg C

Ua-ist

V

Q

0.0 mm3/st

Pump part no.

44-3062

Pump serial no.

(3)

0880052496

GE serial no.

50620-088-52056

Engine model

VRZ_4M41 Right

Rotation

4 cylinders

Pump cylinders

DQ

3

0.0 mm /st

ECU

MELCO

Mode

Adjustment

Pump type

VRZ (12V)

05/04/03 13:23:05 Part number input

Menu

Step information

(9) (10)

Step status

No.

Step name Rough-Q_ADJ

Present step

04

Comment

Standard Q adjustment (GE adjustment)

N

Soll

Soll-cor

Frequency

1000r/min

2.91v

0.00mv

60Hz

Duty 100%

1000r/min

2.91v

0.00mv

60Hz

100%

Next Sequence Select

04 / 31

After values are input, push Next button.

P-cham_ADJ

05

(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

Item

Measured / input value

Unit

Specification

Tolerance

Pump information Specified part no.

N

0 r/min

T

0.0 deg C

Pump part no.

Ua-ist

(3)

V

50620-088-52056

Engine model

VRZ_4M41 Right

Rotation

0.000 MPa

Qo

0.0 I/h

TF

0880052496

GE serial no.

Pump cylinders

Pt

44-6613 44-3062

Pump serial no.

4 cylinders

ECU

MELCO

Mode

Adjustment

Pump type

VRZ (12V)

V 05/04/03 13:23:42 Menu

Step information

(5) (6)

Step status

No.

Step name P-cham_ADJ

Present step

05

Comment

Reconfirmation of PT standard point

Part number input

N

Soll

Soll-cor

Frequency

1000r/min

2.91v

0.00mv

60Hz

Duty 100%

500r/min

2.50v

0.00mv

60Hz

100%

Next Sequence Select

05 / 31 06

After values are input, push Next button

Zero_set

(1)

(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 shaft’s 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.

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

Service tools for pump adjustment Adjustment display

Status

(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 α 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.

P-VRZR- 364

pressure

(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 α 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 [9] TPS zero setting

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

Unit

Specification

Tolerance

Pump information Specified part no.

N

0 r/min

T

0.0 deg C

Ua-ist

V

(3)

Pump part no.

44-3062

Pump serial no.

(4)

V

TPS

V

0880052496

GE serial no.

50620-088-52056

Engine model

VRZ_4M41 Right

Rotation Pump cylinders

VTPS

44-6613

4 cylinders

ECU

MELCO

Mode

Adjustment

Pump type

VRZ (12V)

05/04/03 13:24:16 Zero set

Menu

Step information

(7)

Step status

(8)

Next

No.

Step name

Present step

06

Comment

Confirm initial TPS output.

Sequence Select

Zero_set

06 / 31 07

Part number input

N

Soll

Soll-cor

Frequency

500r/min

2.50v

0.00mv

60Hz

Duty 100%

100r/min

2.41v

0.00mv

60Hz

100%

After values are input, push Next button.

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

Spring TPS output adjustment (TPS standard point shim)

P-VRZR- 137

Th/ness (mm)

0.2 0.6 1.0

Shim part no 149653-0500 (9 443 613 475) 149653-0600 (9 443 612 842) 149653-0700 (9 443 613 476)

Th/ness (mm)

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

Service tools for pump adjustment Adjustment display

Status

Measured / input value

Item

Unit

Specification

Tolerance

Pump information 44-6613

Specified part no.

N

0 r/min

T

0.0 deg C

Ua-ist

V

Pump part no.

44-3062

Pump serial no.

(3)

0880052496

GE serial no.

50620-088-52056

Engine model

VRZ_4M41 Right

Rotation

4 cylinders

Pump cylinders

Pt

0.000 MPa

VTPS

V

TA

ECU

MELCO

Mode

Adjustment

Pump type

VRZ (12V)

mm 05/04/03 13:20:52 Part number input

Menu

Step information

(5) (6)

Step status

No.

Step name Timer_TA

Present step

07

Comment

100r/min

N

Soll

Soll-cor

Frequency

100r/min

2.41v

0.00mv

60Hz

Duty 100%

50r/min

2.41v

0.00mv

60Hz

100%

Next Sequence Select

07 / 31

After values are input, push Next button.

Timer_TA

08

(1)

P-VRZR- 366

TPS

Timer stroke adjusting shim

(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 α 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.

Spring

Pump housing

P-VRZR- 137

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.

Service tools for pump adjustment Adjustment display

Status

Measured / input value

Item

Unit

Specification

Tolerance

Pump information 44-6613

Specified part no.

N

0 r/min

Pump part no.

44-3062

Pump serial no.

T

0.0 deg C

Ua-ist

V

0880052496

GE serial no.

50620-088-52056

Engine model

VRZ_4M41 Right

Rotation

4 cylinders

Pump cylinders

Pt

0.000 MPa

VTPS

V

TA

ECU

MELCO

Mode

Adjustment

Pump type

VRZ (12V)

mm 05/04/03 13:25:27 Part number input

Menu

Step information Step status

No.

Step name Timer_TA

Present step

08

Comment

50r/min

N

Soll

Soll-cor

Frequency

50r/min

2.41v

0.00mv

60Hz

Duty 100%

325r/min

1.53v

0.00mv

60Hz

100%

Next Sequence Select

08 / 31

After values are input, push Next button.

Timer_TA

09

P-VRZR- 367

[11] Non-injection confirmation

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

Unit

Specification

Tolerance

Pump information Specified part no.

N

0 r/min

Pump part no.

(3)

0.0 deg C

Ua-ist

V 0.0 mm3/st

DQ

0.0 mm3/st

0880052496

GE serial no.

50620-088-52056

Engine model

VRZ_4M41 Right

Rotation Pump cylinders

Q

(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 α ist is displayed automatically. (4) Confirm that the Step status field is green. (5) Proceed to the next step.

44-3062

Pump serial no.

T

44-6613

4 cylinders

ECU

MELCO

Mode

Adjustment

Pump type

VRZ (12V)

05/04/03 13:35:08 Menu

Step information

(4) (5)

Step status

No.

Step name Q_characteristics

Present step

17

Comment

Confirm no nozzle injection.

Part number input

N

Soll

Soll-cor

Frequency

2300r/min

0.87v

0.00mv

60Hz

Duty 100%

1900r/min

3.73v

0.00mv

60Hz

100%

Next Sequence Select

17 / 31 18

After values are input, push Next button.

Cor-Q_ADJ

(1)

P-VRZR- 368

- 88 -

ADJUSTMENT [12] Injection quantity compensation point adjustment

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

Unit

Specification

Tolerance

Pump information Specified part no.

N

0 r/min

T

0.0 deg C

Ua-ist

V

Q

0.0 mm3/st

Pump part no.

44-3062

Pump serial no.

(3)

50620-088-52056

Engine model

VRZ_4M41 Right

Rotation

(4)

0.0 mm3/st

0880052496

GE serial no.

Pump cylinders

DQ

44-6613

4 cylinders

ECU

MELCO

Mode

Adjustment

Pump type

VRZ (12V)

05/04/03 13:36:03 Soll-cor

Menu

Step information

(6)

Step status

(7)

Next

No.

Step name Cor-Q_ADJ

Present step

18

Comment

Correction point 10

Sequence Select

18 / 31

Soll

Soll-cor

Frequency

1900r/min

3.73v

0.00mv

60Hz

Duty 100%

1900r/min

1.53v

0.00mv

60Hz

100%

After values are input, push Next button.

Cor-Q_ADJ

19

Part number input

N

(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

0 r/min

Pump part no.

T

0.0 deg C

Ua-ist

V

0880052496

GE serial no.

50620-088-52056

Engine model

VRZ_4M41 Right

Rotation

4 cylinders

Pump cylinders

Q

0.0 mm3/st

DQ

0.0 mm3/st

44-6613 44-3062

Pump serial no.

ECU

MELCO

Mode

Adjustment

Pump type

VRZ (12V)

(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 α 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.

05/04/03 13:36:43 Soll- cor

Menu

Step information Step status

No.

Step name Cor-Q_ADJ

Present step

19

Comment

Correction point 9

Part number input

N

Soll

Soll-cor

Frequency

1900r/min

1.53v

0.00mv

60Hz

Duty 100%

1000r/min

2.91v

0.00mv

60Hz

100%

Next Sequence Select

19 / 31 20

After values are input, push Next button.

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.

44-3062

Pump serial no.

0880052496

GE serial no.

50620-088-52056

Engine model

VRZ_4M41

[13] Compensation ROM interpolation calculation

Right

Rotation

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

44-6613

Pump cylinders

4 cylinders

ECU

MELCO

Mode

Adjustment

Pump type

VRZ (12V)

05/04/03 13:43:00 Menu

Step information Step status

No.

Step name Q-ROM_CAL

Present step

28

Comment

Q-ROM intermediate point calculation

Part number input

N

Soll

Soll-cor

Frequency

0r/min

0.00v

0.00mv

60Hz

Duty 0%

0r/min

0.00v

0.00mv

60Hz

0%

Next Sequence Select

28 / 31 29

After values are input, push Next button.

ROM_overwrite

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.

P-VRZR- 371

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.

- 89 -

ADJUSTMENT [14] Writing to the compensation ROM

Service tools for pump adjustment Adjustment display

Status

Measured / input value

Item

Unit

Specification

Tolerance

(1) Press Step 28/31 to automatically display the step. (2) The adjustment software automatically writes the compensation Q data to the injection pump’s Q adjustment ROM. Advice Never touch the computer, the injection pump or the connecting wire harnesses while writing to the ROM.

Pump information Specified part no. Pump part no.

0880052496

GE serial no.

50620-088-52056

Engine model

VRZ_4M41 Right

Rotation

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

44-6613 44-3062

Pump serial no.

4 cylinders

Pump cylinders ECU

MELCO

Mode

Adjustment

Pump type

VRZ (12V)

05/04/03 13:43:34 Menu

Step information Step status

No.

Step name ROM_overwrite

Present step

29

Comment

Overwrite Q-ROM.

Part number input

N

Soll

Soll-cor

Frequency

0r/min

0.00v

0.00mv

60Hz

Duty 0%

1000r/min

2.91v

0.00mv

60Hz

0%

Next Sequence Select

29 / 31

After values are input, push Next button.

Stop_Q

30

(1)

P-VRZR- 372

[15] M a g n e t v a l v e o p e r a t i o n confirmation

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

Unit

Specification

Tolerance

Pump information Specified part no.

N

0 r/min

T

0.0 deg C

Ua-ist

V

Q

0.0 mm3/st

Pump part no.

44-3062

Pump serial no.

(3)

44-6613

0880052496

GE serial no.

50620-088-52056

Engine model

VRZ_4M41

(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 α ist is displayed automatically.

Right

Rotation

4 cylinders

Pump cylinders ECU

MELCO

Mode

Adjustment

Pump type

VRZ (12V)

05/04/03 13:44:15 Menu

Step information Step status

No.

Step name

Present step

30

Comment

Confirm no nozzle injection when the FCV is OFF.

Stop_Q

Part number input

N

Soll

Soll-cor

Frequency

1000r/min

2.91v

0.00mv

60Hz

Duty 100%

0r/min

2.91v

0.00mv

60Hz

100%

Next Sequence Select

30 / 31 31

After values are input, push Next button.

Q_characteristics

(1)

P-VRZR- 373

(4) Turn the FCV (magnet valve) ON/OFF switch OFF and confirm that non-injection results. Advice To confirm non-injection from the nozzle, look at the monitor screen and confirm that non-injection occurs within a short time (6 ~ 7 seconds).

FCV (magnet valve) ON/OFF switch

P-VRZR- 356

(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.

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

Unit

Specification

Tolerance

Pump information Specified part no.

N

0 r/min

T

0.0 deg C

Ua-ist

V

Pump part no.

44-3062

Pump serial no.

(5)

50620-088-52056

Engine model

VRZ_4M41 Right

Rotation

0.0 mm3/st

0880052496

GE serial no.

Pump cylinders

Q

44-6613

4 cylinders

ECU

MELCO

Mode

Adjustment

Pump type

VRZ (12V)

05/04/03 13:44:15 Menu

Step information

(6) (7)

Step status

No.

Step name

Present step

30

Comment

Confirm no nozzle injection when the FCV is OFF.

Stop_Q

Part number input

N

Soll

Soll-cor

Frequency

1000r/min

2.91v

0.00mv

60Hz

Duty 100%

0r/min

2.91v

0.00mv

60Hz

100%

Next Sequence Select

30 / 31 31

After values are input, push Next button.

Q_characteristics

P-VRZR- 373

- 90 -

ADJUSTMENT [16] Second timing adjustment 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.

Sub-switch

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

(2) Drive gear installation (1) Temporarily assemble the O-ring and bracket to the pump housing.

O-ring

Nuts (3)

Bracket

P-VRZR- 252

(2) Assemble the drive shaft key in the drive shaft’s 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

(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 N·m {17 ~ 18.7 kgf·m}

Wrench

Tool name Wrench

Torque wrench

P-VRZR- 256

- 92 -

Part no 157917-4620

Remarks

ADJUSTMENT (3) Injection pump installation (1) Attach the stand to the pump test bench. Stand

Tool name Stand

Part no

Remarks

105781-0890

P-VRZR- 258

(2) Attach the injection pump to the stand. (3) Pull the stand’s handle as shown in the figure to fix the injection pump.

Stand

P-VRZR- 259

(4) Remove the CPV from cylinder B and attach the pipe assembly and the gasket.

Pipe assembly

Tool name

Part no

Pipe assembly

157845-9520

Remarks

P-VRZR- 260

(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.

Plugs

Test oil hose

P-VRZR- 261

- 93 -

ADJUSTMENT (7) Connect the controller assembly’s main harness and intermediate harness to the injection pump’s GE connector.

Main harness

Tool name

Intermediate harness

Part no

Main harness

157966-4920

Intermediate harness

157966-5720

Remarks

P-VRZR- 262

(8) Align the adjusting device’s pin hole with the injection pump bracket’s pin. In this position, attach the adjusting device to the injection pump’s bracket and fix using the bolts.

Chamfered tooth

Adjusting device

Tool name

Rack

Pin

Adjusting device

Rack teeth

Pin hole

P-VRZR- 263

Sub-switch

Part no

Remarks

105793-0020

Advice When aligning the adjusting device’s pin hole with the bracket’s pin, position the adjusting device’s rack teeth on either side of the drive gear’s chamfered tooth. (4) Second timing adjustment (1) Turn the controller unit’s 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

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

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

Unit

Specification

Tolerance

Pump information Specified part no.

N

0 r/min

T

0.0 deg C

Ua-ist

V

Pump part no.

44-3062

Pump serial no.

50620-088-52056

Engine model

VRZ_4M41 Right

Pump cylinders

Q

0.0 mm /st

DQ

0.0 mm3/st

0880052496

GE serial no.

Rotation

3

44-6613

4 cylinders

ECU

MELCO

Mode

Adjustment

Pump type

VRZ (12V)

05/04/03 13:44:46 Menu

Step information Step status

No.

Step name Q_characteristics

Present step

31

Comment

Second timing

Part number input

N

Soll

Soll-cor

Frequency

0r/min

2.91v

0.00mv

60Hz

Duty 100%

Next Sequence

31 / 31

Select

_

After values are input, push Next button.

Adjustment finished

(3)

P-VRZR- 376

- 94 -

ADJUSTMENT (4) Loosen the injection pump bracket installation nuts.

Nuts (3)

P-VRZR- 264

(5) Loosen the bolt preventing drive shaft rotation and remove the FBB plate.

FBB plate Bolt preventing drive shaft rotation

P-VRZR- 265

Pipe assembly

(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 B’s pipe assembly at a rate of 1 drop / 3 seconds.

Adjusting device

P-VRZR- 266

(8) Tighten the bolt preventing drive shaft rotation to fix the drive shaft. Specified torque: 27 ~ 35 N·m {2.8 ~ 3.6 kgf·m}

Bolt preventing drive shaft rotation

P-VRZR- 267

- 95 -

ADJUSTMENT Nuts (3)

(9) Tighten the bracket nuts. Specified torque: 34 ~ 39 N·m {3.5 ~ 4.0 kgf·m}

P-VRZR- 268

(10) Mark the timing mark on the injection pump and the bracket. Advice Erase the previous mark.

Timing mark

P-VRZR- 269

FBB plate

(11) Loosen the bolt preventing drive shaft rotation, install the FBB plate and fix the FBB plate by tightening the bolt preventing drive shaft rotation. Specified torque: 10 ~ 15 N·m {1.0 ~ 1.5 kgf·m} (12) Turn the test oil switch OFF.

Bolt preventing drive shaft rotation

P-VRZR- 270

(13) Measure T on the pump test bench and input the value. Note: U α ist is displayed automatically. (14) Confirm that the Step status field is green. (15) Proceed to the next step.

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

Unit

Specification

Tolerance

Pump information Specified part no.

N

0 r/min

T

0.0 deg C

Ua-ist

V

Pump part no.

44-3062

Pump serial no.

(13)

0.0 mm3/st

DQ

0.0 mm3/st

0880052496

GE serial no.

50620-088-52056

Engine model

VRZ_4M41 Right

Rotation Pump cylinders

Q

44-6613

4 cylinders

ECU

MELCO

Mode

Adjustment

Pump type

VRZ (12V)

05/04/03 13:44:46 Menu

Step information

(14) (15)

Step status

No.

Step name Q_characteristics

Present step

31

Comment

Second timing

Part number input

N

Soll

Soll-cor

Frequency

0r/min

2.91v

0.00mv

60Hz

Duty 100%

Next Sequence

31 / 31

Select

_

After values are input, push Next button.

Adjustment finished

P-VRZR- 376

- 96 -

ADJUSTMENT

MC-02 TESTER

Adjustment result 44-6613 44-3062

Specified part no. Pump part no.

No. Result

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

Pump serial no. GE serial no.

Step name

N r/min

ECU values Uasoll Soll-cor TCVF V mv Hz

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

0880052496 50620-088-52056

DTCV %

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

N r/min

T DegC

Uaist V

Test complete

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

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 want0 to print0.0 and save test record? 0.00 100 0.00 100 0 0.0 0.0 100 OK 0 0.0Cancel 0.00 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 0.00 100 0 0.0 0.0

0.000

0.0

0.000

0.0

VTPS V

TPS V

TF V

0.00

0.0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

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

0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0

If no further measurements are required, select Next button. To repeat a measurement, select Repeat button and input step number.

Next

Repeat

Step number

Adjustment necessary

TA mm

(1)

P-VRZR- 377

(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 unit’s sub-switch OFF. (5) Turn the controller unit’s main switch OFF.

(6) Injection pump removal (1) Remove the adjusting device from the injection pump’s drive gear.

Adjusting device

P-VRZR- 271

(2) Replace cylinder B’s pipe assembly with the CPV. At this time, replace the gasket with a new one.

CPV

Pipe assembly

P-VRZR- 272

- 97 -

ADJUSTMENT (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.

Main harness Plug

Intermediate harness

Test oil hose P-VRZR- 273

(5) Install the Q adjustment ROM to the pump housing. Note: Removing the inlet adapter facilitates installation. (6) Tighten the Q adjustment ROM’s torx bolts. Specified torque: 2 ~ 3 N·m {0.2 ~ 0.3 kgf·m}

Torx bolts (4)

Q adjustment ROM

Tool name

Pump housing Bit

Holder

P-VRZR- 393

Part no

Holder

157915-9820

Bit

157915-9301 T20

Remarks

(7) Connect the overflow valve’s bypass hose to the injection pump. (8) Tighten the overflow valves using a torque wrench. Specified torque: 20 ~ 29 N·m {2 ~ 3 kgf·m}

Overflow valve Bypass hose

Overflow valve P-VRZR- 274

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

Stand Injection pump

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 (1) Turn the controller unit’s sub-switch ON. (2) Supply test oil to the injection pump at the specified pressure of 20 kPa {0.2 kgf/cm2}.

Sub-switch

P-VRZR- 397

(3) Select ‘Manual operation’ on the menu display.

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

(3)

Manual operation

Workshop name registration

Exit

P-VRZR- 346

- 99 -

ADJUSTMENT

MC-02 TESTER

Manual operation ECU reader data Item

Value

Unit

GE Vist Item

Value

Unit

TF

(4)

Item

Value

Unit

Value

Unit

TPS Vist

V

Item

Np

deg C

V

r/min

Select ECU ROM COVEC-F MITSUBISHI 12V

VRZ MITSUBISHI 12V

ROM COVEC-F MAZDA 12V

ECU configuration data

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

Input

GE Soll GE Soll-cor

V mV

TCV Duty

%

TCV Frequency

Hz

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

Initialize ECU

Menu

P-VRZR- 348

Nuts (3)

(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 keyboard’s ‘Enter’ key. (7) Press the ‘TCV Duty’ button and input ‘100’ into the field. Press the keyboard’s ‘Enter’ key. (8) Press the ‘TCV Frequency’ button and input ‘60’ into the field. Press the keyboard’s ‘Enter’ key. Advice Values must be input for GE soll, TCV Duty and TCV Frequency. (9) Loosen the injection pump bracket installation nuts.

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

(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 B’s pipe assembly at a rate of 1 drop /3 seconds.

Adjusting device

P-VRZR- 266

- 100 -

ADJUSTMENT

Bolt preventing drive shaft rotation

(13) Tighten the bolt preventing drive shaft rotation to fix the drive shaft. Specified torque: 27 ~ 35 N·m {2.8 ~ 3.6 kgf·m}

P-VRZR- 267

Nuts (3)

(14) Tighten the bracket nuts. Specified torque: 34 ~ 39 N·m {3.5 ~ 4.0 kgf·m}

P-VRZR- 268

(15) Mark the timing mark on the injection pump and the bracket. Advice Erase the previous mark.

Timing 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 N·m {1.0 ~ 1.5 kgf·m} (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

Preparation

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Part no. input and installation confirmation

Warming-up operation

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Pump chamber pressure confirmation

TPS confirmation

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Timer stroke confirmation

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Non-injection confirmation

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Injection quantity confirmation

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Finish

- 102 -

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Magnet valve operation confirmation Inspection result

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See page 103 [1]

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

See page 106 [5]

See page 107 [6]

See page 107 [7]

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

See page 109 [11]

See page 110 [12]

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 pump’s 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 actuator’s 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

Test oil hose Injection system piping

P-VRZR- 353

ROM harness COM2

COM1

Controller unit Controller assembly harness for VRZ adjustment

P-VRZR- 354

(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 assembly’s wire harness and intermediate harness to the injection pump’s connectors. (Refer to page 70 for the controller assembly’s wiring.) (4) Connect the ROM controller’s wire harness and intermediate harness to the injection pump’s VRZ EEPROM connector. (5) Connect the FCV GND harness to the controller assembly’s 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.

- 103 -

INSPECTION (8) Reconfirm that the coupling and the fixing stand bolts and nuts are securely tightened. (9) Set the 20NP pump tester’s test oil outlet temperature at 45°C. (10) Set the cooling unit oil delivery pressure lever at ‘80 kPa {0.8 kgf/cm2}’ or less.

Fixing stand

P-VRZR- 355

(11) Connect the wire harness to the controller unit’s 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.

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

ECU for VRZ type injection pump No. 1 ~ No. 4 change-over switch P-VRZR- 397

[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

(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.

MC-02 TESTER

Precaution Password is required to actuate adjustment tools. Input password and press ENTER key.

(3) P-VRZR- 357

- 104 -

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

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

Service tools for pump adjustment Version1.0

RBAJ

and

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

ROM COVEC-F MITSUBISHI 12V Inspection/adjustment

(1)

VRZ MITSUBISHI 12V Inspection/adjustment

input

ROM COVEC-F MAZDA 12V Inspection/adjustment

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)

446613

Pump serial no. (10 digits)

Pump part no. (last 6 digits)

443062

GE serial no. (13 digits)

System specifications Rotation Pump cylinders ECU

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

Inspection

Mode

(4) (5)

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*

VRZ_4M41 Right 4 cylinders MELCO

Engine model

5555555555 6666666666666

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 GE’s serial number (13 digits) and press ‘Enter’. (6) Press the ‘Next’ key.

P-VRZR- 378

(7) Confirm that the screen changes to the injection system piping display.

MC-02 TESTER

Setup confirmation Installation confirmation Click on appropriate item and explanatory illustration is displayed. 1. Injection system piping 2. Overflow piping

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

3. Adjustment controller wiring 3

4. Operation sequence

2

4

If necessary to proceed after confirmation, push Next button. 1

Menu Back

Next

P-VRZR- 359

- 105 -

INSPECTION [5] Warming-up operation

Service tools for pump adjustment Adjustment display

Status

Measured / input value

Item

Unit

Specification

Tolerance

Pump information 44-8813

Specified part no.

N

0 r/min

Pump part no.

44-3052

Pump serial no.

T

0.0 deg C

Ua-ist

V

(4)

5555555555

GE serial no.

66666-666-66666

Engine model

VRZ_4M41 Right

Rotation

4 cylinders

Pump cylinders

Q

0.0 mm3/st

ECU

MELCO

Mode

Adjustment

Pump type

VRZ (12V)

02/04/03 14:07:56 Part number input

Menu

Step information

(5)

Step status

(6)

Next

No.

Step name

Present step

01

Comment

Check for fuel leaks.

Sequence Select

Warm-up

01 / 26

Soll

Soll-cor

Frequency

300r/min

2.80v

0.00mv

60Hz

Duty 100%

1000r/min

2.91v

0.00mv

60Hz

100%

After values are input, push Next button.

Warm-up

02

N

(2)

P-VRZR- 379

(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 α ist is displayed automatically. (10) Confirm injection. (11) Confirm that no fuel leaks from the injection pump fuel piping connections.

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

Unit

Specification

Tolerance

Pump information Specified part no.

N

0 r/min

T

0.0 deg C

Ua-ist

V

Pump part no.

(9)

66666-666-66666

Engine model

VRZ_4M41 Right

Rotation

0.0 mm3/st

5555555555

GE serial no.

Pump cylinders

Q

44-8813 44-3052

Pump serial no.

4 cylinders

ECU

MELCO

Mode

Adjustment

Pump type

VRZ (12V)

02/04/03 14:09:35 Menu

Step information

(13) (14)

Step status

No.

Step name

Present step

02

Comment

Warm-up

Warm-up

Part number input

N

Soll

Soll-cor

Frequency

1000r/min

2.91v

0.00mv

60Hz

Duty 100%

1000r/min

2.91v

0.00mv

60Hz

100%

Next Sequence Select

02 / 26 03

After values are input, push Next button.

P-cham_ADJ

(7)

(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 α ist is displayed automatically. (5) Confirm that the Step status field is green. (6) Proceed to the next step. Advice If U α 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 α ist values are as specified. Note: If not as specified after confirming U α ist several times, the GE may be faulty.

CAUTION

P-VRZR- 380

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

Service tools for pump adjustment Adjustment display

Status

Measured / input value

Item

Unit

Specification

Tolerance

Pump information 44-8813

Specified part no.

N

0 r/min

T

0.0 deg C

Ua-ist

V

Pump part no.

44-3052

Pump serial no.

(3)

5555555555

GE serial no.

66666-666-66666

Engine model

VRZ_4M41 Right

Rotation

4 cylinders

Pump cylinders

Pt

0.000 MPa

Qo

0.0 I/h

TF

ECU

MELCO

Mode

Adjustment

Pump type

VRZ (12V)

V 02/04/03 14:10:05 Part number input

Menu

Step information

(5)

Step status

(6)

Next

No.

Step name P-cham_ADJ

Present step

03

Comment

Reconfirm PT standard point.

Sequence Select

03 / 26

Soll

Soll-cor

Frequency

1000r/min

2.91v

0.00mv

60Hz

Duty 100%

500r/min

2.50v

0.00mv

60Hz

100%

After values are input, push Next button.

Zero_set

04

N

(1)

P-VRZR- 386

Item

Measured / input value

Unit

Specification

Tolerance

Pump information Specified part no.

N

(3)

0 r/min

Pump part no.

T

0.0 deg C

Ua-ist

V V

TPS

V

50620-088-52056

Engine model

VRZ_4M41 Right

Rotation

MELCO

Mode

Adjustment

Pump type

VRZ (12V)

05/04/03 14:10:51 Zero set

(6)

4 cylinders

ECU

(4) (5)

0880052496

GE serial no.

Pump cylinders

VTPS

44-6613 44-3062

Pump serial no.

Menu

Step information Step status

No.

Step name

Present step

04

Comment

Push Zero set button.

Zero_set

Part number input

N

Soll

Soll-cor

Frequency

500r/min

2.50v

0.00mv

60Hz

Duty 0%

100r/min

2.41v

0.00mv

60Hz

0%

Next Sequence Select

04 / 26 05

(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 α 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.

[7] TPS confirmation

Service tools for pump adjustment Adjustment display

Status

pressure

After values are input, push Next button.

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 α 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.

N

0 r/min

Pump part no.

T

(3)

0.0 deg C

Ua-ist

V

50620-088-52056

Engine model

VRZ_4M41 Right

Rotation

0.000 MPa

VTPS

V

TA

0880052496

GE serial no.

Pump cylinders

Pt

44-6613 44-3062

Pump serial no.

4 cylinders

ECU

MELCO

Mode

Adjustment

Pump type

VRZ (12V)

mm 05/04/03 14:11:50 Menu

Step information

(5) (6)

Step status

No.

Step name Timer_TA

Present step

05

Comment

100r/min

Part number input

N

Soll

Soll-cor

Frequency

100r/min

2.41v

0.00mv

60Hz

Duty 100%

50r/min

2.41v

0.00mv

60Hz

100%

Next Sequence Select

05 / 26 06

After values are input, push Next button.

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 α 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

Unit

Measured / input value

Specification

Tolerance

Pump information 44-6613

Specified part no.

N

0 r/min

Pump part no.

44-3062

Pump serial no.

T

0.0 deg C

Ua-ist

V

0880052496

GE serial no.

50620-088-52056

Engine model

VRZ_4M41 Right

Rotation

4 cylinders

Pump cylinders

Pt

0.000 MPa

VTPS

V

TA

ECU

MELCO

Mode

Adjustment

Pump type

VRZ (12V)

mm 05/04/03 14:11:50 Part number input

Menu

Step information Step status

No.

Step name Timer_TA

Present step

05

Comment

100r/min

N

Soll

Soll-cor

Frequency

100r/min

2.41v

0.00mv

60Hz

Duty 100%

50r/min

2.41v

0.00mv

60Hz

100%

Next Sequence

05 / 26

Select

06

After values are input, push Next button.

Timer_TA

P-VRZR- 381

[9] Non-injection confirmation Service tools for pump adjustment Adjustment display

Status

Measured / input value

Item

Unit

Specification

Tolerance

44-8813

Specified part no.

N

0 r/min

Pump part no.

44-3052

Pump serial no.

T

(3)

0.0 deg C

Ua-ist

V

5555555555

GE serial no.

66666-666-66666

Engine model

VRZ_4M41 Right

Rotation

4 cylinders

Pump cylinders

Q

0.0 mm /st

DQ

0.0 mm3/st

3

(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 α ist is displayed automatically. (4) Confirm that the Step status field is green. (5) Proceed to the next step.

Pump information

ECU

MELCO

Mode

Adjustment

Pump type

VRZ (12V)

02/04/03 14:13:11 Part number input

Menu

Step information

(4) (5)

Step status

No.

Step name Q_characteristics

Present step

15

Comment

Confirm no nozzle injection.

N

Soll

Soll-cor

Frequency

2300r/min

0.87v

0.00mv

60Hz

Duty 100%

1000r/min

2.91v

-34.18mv

60Hz

100%

Next Sequence Select

15 / 26

After values are input, push Next button.

Cor-Q_INSP

16

(1)

P-VRZR- 382

[10] Injection quantity confirmation

Service tools for pump adjustment Adjustment display

Status

Measured / input value

Item

Unit

Specification

Tolerance

Pump information 44-8813

Specified part no.

N

0 r/min

T

0.0 deg C

Ua-ist

V

Pump part no.

44-3052

Pump serial no.

(3)

5555555555

GE serial no.

66666-666-66666

Engine model

VRZ_4M41 Right

Rotation

4 cylinders

Pump cylinders

Q

0.0 mm3/st

DQ

0.0 mm3/st

ECU

MELCO

Mode

Adjustment

Pump type

VRZ (12V)

02/04/03 14:13:47 Part number input

Menu

Step information

(4)

Step status

(5)

Next

No.

Step name Cor-Q_INSP

Present step

16

Comment

Correction point 8

Sequence Select

16 / 26 17

N

Soll

Soll-cor

Frequency

1000r/min

2.91v

-34.18mv

60Hz

Duty 100%

1900r/min

3.73v

34.18mv

60Hz

100%

After values are input, push Next button.

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 α 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.

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

Unit

Specification

Tolerance

Pump information Specified part no.

N

0 r/min

Pump part no.

T

0.0 deg C

Ua-ist

V 0.0 mm3/st

DQ

0.0 mm3/st

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.

5555555555

GE serial no.

66666-666-66666

Engine model

VRZ_4M41 Right

Rotation Pump cylinders

Q

44-8813 44-3052

Pump serial no.

4 cylinders

ECU

MELCO

Mode

Adjustment

Pump type

VRZ (12V)

02/04/03 14:13:47 Menu

Step information Step status

No.

Step name Cor-Q_INSP

Present step

16

Comment

Correction point 8

Part number input

N

Soll

Soll-cor

Frequency

1000r/min

2.91v

-34.18mv

60Hz

Duty 100%

1900r/min

3.73v

34.18mv

60Hz

100%

Next Sequence Select

16 / 26 17

After values are input, push Next button.

Cor-Q_INSP

P-VRZR- 383

- 108 -

INSPECTION [11] M a g n e t v a l v e o p e r a t i o n confirmation

Service tools for pump adjustment Adjustment display

Status

Measured / input value

Item

Unit

Specification

Tolerance

Pump information Specified part no.

N

0 r/min

T

0.0 deg C

Ua-ist

V

Pump part no.

44-3052

Pump serial no.

(3)

66666-666-66666

Engine model

VRZ_4M41

(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 α ist is displayed automatically.

Right

Rotation

0.0 mm3/st

5555555555

GE serial no.

Pump cylinders

Q

44-8813

4 cylinders

ECU

MELCO

Mode

Adjustment

Pump type

VRZ (12V)

02/04/03 14:14:59 Menu

Step information Step status

No.

Step name

Present step

26

Comment

Confirm no nozzle injection when the FCV is OFF.

Stop_Q

Part number input

N

Soll

Soll-cor

Frequency

1000r/min

2.91v

0.00mv

60Hz

Duty 100%

Next Sequence

26 / 26

Select

_

After values are input, push Next button.

Inspection finished

(1)

P-VRZR- 384

(4) Turn the FCV (magnet valve) ON/OFF switch OFF and confirm that non-injection results. Advice To confirm non-injection from the nozzle, look at the monitor screen and confirm that non-injection occurs within a short time (6 ~ 7 seconds).

FCV (magnet valve) ON/OFF switch

P-VRZR- 356

(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.

Service tools for pump adjustment Adjustment display

Status

Item

Measured / input value

Unit

Specification

Tolerance

Pump information Specified part no.

N

0 r/min

T

0.0 deg C

Ua-ist

V

Pump part no.

44-3052

Pump serial no.

(5)

66666-666-66666

Engine model

VRZ_4M41 Right

Rotation

0.0 mm3/st

5555555555

GE serial no.

Pump cylinders

Q

44-8813

4 cylinders

ECU

MELCO

Mode

Adjustment

Pump type

VRZ (12V)

02/04/03 14:14:59 Menu

Step information

(6)

Step status

(7)

Next

No.

Step name

Present step

26

Comment

Confirm no nozzle injection when the FCV is OFF.

Stop_Q

Sequence

26 / 26

Select

_

Part number input

N

Soll

Soll-cor

Frequency

1000r/min

2.91v

0.00mv

60Hz

Duty 100%

After values are input, push Next button.

Inspection finished

P-VRZR- 384

- 109 -

INSPECTION [12] Inspection result

MC-02 TESTER

Inspection result 44-8813 44-3052

Specified part no. Pump part no.

No. Result

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

Pump serial no. GE serial no.

Step name

N r/min

ECU values Uasoll Soll-cor TCVF V mv Hz

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

5555555555 66666-666-66666

DTCV %

N r/min

T DegC

Uaist v

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 want0 to print0.0 and save test record? 0.00 100 0.00 100 0 0.0 0.0 100 OK 0 0.0Cancel 0.00 0.0 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

Adjustment necessary

Test complete

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

0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

VTPS v

TA mm

TF V

0.00 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

0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0

If no further measurements are required, select Next button. To repeat a measurement, select Repeat button and input step number. Step number

TPS V

0.0

Next

Repeat

(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 unit’s sub-switch OFF. (5) Turn the controller unit’s main switch OFF.

- 110 -

TIGHTENING TORQUES

Units: N·m {kgf·m} 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 - φ6.5 1 2 - φ7 2 2 - φ7.5 3 2 - φ8 4 2 - φ8.5 5 2 - φ9 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)

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

(8)

Manufactured by Bosch Automotive Systems Corporation VRZ type injection pump Number of cylinders Plunger diameter Electronic governor Maximum controlled governor speed (r/min) Direction of pump rotation R: clockwise viewed from drive side L: counter clockwise viewed from drive side (8): Proper number

- 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