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Pub. No.

EE14E-11162

SERVICE MANUAL REPAIR SERVICE


& MAINTENANCE

VRZ
WARNINGS
The following definitions and warning signs are used in this service manual.
These are extremely important to safe operation.
Important points are described to prevent bodily injury and property damage.
They must be fully understood before beginning VRZ maintenance.

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

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

Advice Procedures that must be performed to enable the best possible VRZ
maintenance.
Note Information assisting in the best possible VRZ maintenance.
FOREWORD
This service manual describes the disassembly, The contents of the manual, including
inspection, reassembly and adjustment of the illustrations, drawings and specifications were
VRZ (radial plunger system position-control the latest available at the time of printing.
distributor type fuel injection pump). The right is reserved to make changes in
Refer to the separate service manuals listed specifications and procedures at any time
below to facilitate VRZ type injection pump without notice.
maintenance.
This manual is intended for use by vehicle BOSCH K.K.
maintenance technicians or persons with an Sales Automotive Aftermarket Division
adequate knowledge of injection pumps.

Service manual Publication number


VRZ Construction and Operation EE14E-11150
INJECTION PUMP TEST BENCH 10NP & 20 NP, Operation EC18E-11081
CONTINUOUS MEASURING DEVICE ZCM & ZCD, Operation EC18E-11091
CONTROLLER ASSEMBLY MC-02, FOR VRZ & COVEC-F EC14E-11022
WITH EEP-ROM, Operation
MC-02 TESTER SOFTWARE, ADJUSTMENT AND INSPECTION ED14E-11011
DATA, FOR VRZ AND COVEC-F WITH EEP-ROM, Installation
ECU ASSEMBLY, ADJUSTMENT AND INSPECTION DATA, ED14E-11021
FOR VRZ AND COVEC-F WITH EEP-ROM, Installation
CONTENTS
Page Page
SERVICE PRECAUTIONS.................... 1 INSPECTION .................................... 102
SPECIAL TOOLS ................................. 2 TIGHTENING TORQUES ................. 111
1. DISASSEMBLY, INSPECTION AND
PART NUMBER EXPLANATION ..... 112
REASSEMBLY TOOLS .......................... 2
1. INJECTION PUMP ASSEMBLY
2. ADJUSTMENT TOOLS ........................... 9
NUMBER ............................................ 112
DISASSEMBLY................................... 15 2. BOSCH TYPE NUMBER .................... 112
1. PREPARATION .................................... 15
2. EXPLODED VIEW ................................ 15
3. ENGINE DRIVE GEAR REMOVAL....... 16
4. 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
SERVICE PRECAUTIONS

[1] Carrying the injection pump


Never knock or drop the injection pump
when carrying it.

Injection pump

P-VRZR- 320

When carrying the injection pump, hold the


GE actuator
pump by the bottom of the pump body.
CAUTION
Never hold the pump by the GE actuator or
the harnesses.
Holding the pump by these components may
result in damage or injury.
Wire harness

Pump body
P-VRZR- 321

GE actuator
[2] Disassembly and reassembly
Only the mechanical components of the
injection pump body can be disassembled
and reassembled.
Advice
Do not disassemble the GE actuator other
than directed in this manual.
The GE actuator consists of electrical
components. Do not damage them.

Injection pump
P-VRZR- 322

Harness connectors When cleaning the injection pump, do not


GE actuator clean the GE actuator, the harnesses, or the
harness connectors using fuel oil. Use only
clean waste cloth.

Wire harness

Injection pump
P-VRZR- 323

-1-
SPECIAL TOOLS

1. DISASSEMBLY, INSPECTION AND REASSEMBLY TOOLS


[1] Tool use locations

20 21 18 31 30

19
32
34
10
22
33

7
9
27
24

6
26 29
13

8 15

11
14

12

37

28 25
36
23 16
3, 4

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
RBAJ part no Bosch part no Part name Qty Remarks
no
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: 25)
10 157928-4120 9 442 612 299 Extractor 1 For removing oil seal (shaft dia: 25)
11 157829-3520 9 681 610 171 Measuring device 1 For measuring rotor's axial play (tool for
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: 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 9 442 612 301 Spacer 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: 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;
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
RBAJ part no Bosch part no Part name Qty Remarks
no
30 157915-9700 9 681 610 686 Socket 1 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 2. 157945-2020 3. 157944-7100


(9 681 610 317) (9 681 610 812) (9 681 610 340)
Universal vise Bracket Bracket

4. 157944-7200 5. 010010-2220 6. 157913-7000


(9 681 610 797) (9 442 612 366) (0 986 612 682)
Bracket Bolt Socket wrench

7. 157928-4320 8. 157914-3600 9. 157928-4000


(9 442 612 367) (9 681 610 678) (9 442 612 368)
Feed pump holder Socket wrench Oil seal guide

-5-
SPECIAL TOOLS

10. 157928-4120 11. 157829-3520 12. 157845-8900


(9 442 612 299) (9 681 610 171) (9 681 610 626)
Extractor Measuring device Adapter

13. 105782-4530 14. 157917-4620 15. 157848-2300


(9 680 610 094) (9 681 610 710) (9 681 611 027)
Measuring device Wrench Oil seal guide

46

25 75

16. 157926-2421 17. 157927-4500 18. 157928-5820


(9 681 610 773) (9 443 613 008) (9 443 613 397)
Extractor Puller Hook

-6-
SPECIAL TOOLS

19. 157928-3120 20. 157928-3620 21. 157928-4200


(9 442 612 297) (9 442 612 298) (9 442 612 369)
Clip Holder Guide

22. 157928-4500 23. 157928-4700 24. 105782-4540


(9 442 612 300) (9 442 612 301) (9 680 610 095)
Set screw Spacer Measuring device

25. 157847-0820 26. 157915-9820 27. 157915-9201


(9 442 612 370) (9 681 610 687) (9 681 610 684)
Coupling Holder Bit

-7-
SPECIAL TOOLS

28. 157915-9301 29. 157915-9600 30. 157915-9700


(9 681 610 685) (9 681 611 015) (9 681 610 686)
Bit Bit Socket

31. 157928-4800 32. 157917-4920 33. 157977-8000


(9 442 612 302) (9 681 610 711) (9 681 610 829)
Plate Wrench Adapter

34. 026512-1640 35. 157971-0500 36. 157924-8520 37. 157928-4400


(9 421 617 041) (9 443 613 408) (9 681 611 028) (9 442 612 371)
Gasket Clip Base Pliers
172
138

-8-
SPECIAL TOOLS

2. ADJUSTMENT TOOLS
[1] Tool use locations

9
8

7
2

4
3

P-VRZR- 325

-9-
SPECIAL TOOLS

[2] Adjustment tool table


(1) Bosch Automotive System specifications
Key
RBAJ part no Bosch part no Part name Qty Remarks
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 1.6 outer dia 6 - length 450mm
3 157641-6820 9 443 612 974 Joint assembly 1 The VP44 adjustment tool Bosch part no
0 986 611 876 (key no. 4 in the table below)
can also be used instead of this tool.
4 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 Bosch part no Part name Qty Remarks

1 1 687 010 126 VE pump overflow accessory 1 Three-way valve


set
2 1 688 901 035 Nozzle, nozzle holder assembly 4 Bosch type X... for VP44 test device,
orifice 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 benchs flywheel to the drive stand.

- 10 -
SPECIAL TOOLS

1. 105796-0000 2. 157808-4720 3. 157641-6820


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

4. 157811-9020 5. 157829-0820 6. 157971-1020


(9 681 610 453) (9 681 610 336) (9 443 613 442)
Flange Adjusting device Piping assembly

200
M12X1.5

11

M10X1.0

7. 105781-0890 8. 105793-0020 9 . 157845-9520


(9 680 610 087) (9 681 610 418) (9 681 610 630)
Stand Adjusting device Pipe assembly

- 11 -
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 1-1: 157966-4020 1-1-1: 157966-4120 (9 443 613 447)
(9 680 610 209) (9 443 613 446) 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 Qty
RBAJ part no Bosch part no Part name Remarks
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 -
SPECIAL TOOLS

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

1-1-1 157966-4120 1-1-2 157966-4420 1-1-3 157966-4520


(9 443 613 447) (9 443 613 448) (9 443 613 449)
Controller unit Wire harness Wire harness

1-1-4 157966-4620 1-1-5 157966-4720 1-1-6 157966-4820


(9 443 613 450) (9 443 613 451) (9 443 613 452)
Wire harness Wire harness Wire harness

2000
2000

1000

1-1-7 157966-4920 1-1-8 157966-5020 1-1-9 157966-5100


(9 443 613 453) (9 443 613 454) (9 443 613 455)
Main harness Main harness CD-ROM

2000
2990

- 13 -
SPECIAL TOOLS

1-3 157966-3820
(9 443 613 457)
ECU assembly (4M41)

[4] Intermediate harness table


Key
RBAJ part no Bosch part no Part name Qty Remarks
no
1 157966-5720 9 443 613 460 Intermediate 1 4M41 VRZ GE
harness
2 157966-2421 9 443 613 462 Intermediate 1 For 4M41, 4D56 ROM
harness

1. 157966-5720 2. 157966-2421
(9 443 613 460) (9 443 613 462)
Intermediate harness Intermediate harness
(4M41) (4M41, 4D56 ROM)

200
1100

- 14 -
DISASSEMBLY

1. PREPARATION
Clean the outside of the injection pump Lay out the disassembled parts neatly and
before disassembly, removing all grease and sequentially on the work bench, labelling
dirt. Drain the fuel oil from the pump. them if necessary, to facilitate later
Keep the work bench and workshop clean reassembly.
and tidy. Prepare a container of clean fuel oil for
Before beginning disassembly, record plungers, delivery valves and other precision
performance data for later reference to parts.
facilitate the diagnosis of malfunctions and
defects, if any, in the pump.

2. EXPLODED VIEW

153
150
65
161 150/8
152 956
151
121 66
120 955
37
35
36
948 949 34
33 160
110 38 100 122
111 50 22 101 130
112 878S

50 102
949 32
31
55 911 910
30
56 46 35
45
905
50 11 912
50 17 914 3
51 2
50 205 1 922
53 5
54 60 41
62 6 40
61 16 7 80/7 42
8 43
10
9
25 83
18
20

82
15 80/8
931 930
80
920

26
27 810S 856S 925 923

P-VRZR- 326

- 15 -
DISASSEMBLY

Injection pump body 3. ENGINE DRIVE GEAR REMOVAL


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

P-VRZR- 300

Bolt (M6x1)
(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
Wrench A temporarily.)
Drive gear
Tool name Part no Remarks
Wrench A 157917-4920
Wrench B P-VRZR- 301 Wrench B 157917-4620

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

Bolt (M6x1) (4) Remove wrenches A and B and the torque


wrench from the drive gear.
(5) Install wrench B so that the main gear and
the sub-gear are in the center of wrench B.
(6) Remove the bolt from the drive gear.
(7) Align the main gear and the sub-gear using
wrench A, then install the bolt and tighten
Wrench A to the specified torque.
Drive gear Specified torque: 9 ~ 13 Nm
{0.9 ~ 1.3 kgfm}
Wrench B P-VRZR- 318

- 16 -
DISASSEMBLY

(8) Remove wrench A.

Sub-gear
P-VRZR- 302

(9) Remove the roundnut (SW21) fixing the


drive gear.
Socket wrench

P-VRZR- 303

(10) Assemble puller A in the gap between the


Bolt
drive gear and the bracket and loosely fix
the bolts.
Tool name Part no Remarks
Puller 157927-4500 Parts A and B
Puller A

P-VRZR- 304

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

P-VRZR- 305

- 17 -
DISASSEMBLY

Drive gear (12) Tighten the puller bolt to remove the drive
gear.
Advice
Hold the puller so that it does not drop when
the gear is removed from the drive shaft.

Bolt

P-VRZR- 306

(13) Remove the drive shaft key.

Key

Drive shaft
P-VRZR- 307

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


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

Nuts (3)

O-ring

P-VRZR- 319

- 18 -
DISASSEMBLY

Remove overflow valve 4. DISASSEMBLY


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

Remove overflow valve


from here.

P-VRZR- 016

Bolts (2) Universal vise (2) Attach bracket A and bracket B to the
universal vise (and fix temporarily).
(3) Attach bracket C to bracket A and bracket B
and tighten bracket As and bracket Bs bolts.
Tool name Part no Remarks
Universal vise 157944-8521
Bracket A Bracket A 157944-7100
Position at front.
Bracket B 157944-7200
Bracket C 157945-2020
Bracket B Bracket C
P-VRZR- 017 Bolt 010010-2220 M10x1.5

Injection pump (4) Attach the injection pump to bracket C.

Bracket C

P-VRZR- 309

TCV harness connector (5) Remove the bracket bolts.


(6) Remove the TCV harness connector.

Bracket bolts

P-VRZR- 310

- 19 -
DISASSEMBLY

Grommet Nut [2] Magnet valve removal


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 cover [3] GE actuator removal


GE actuator Torx bolts (6)
(1) Remove the GE actuators torx bolts and
Spring washers (6) spring washers.
Tool name Part no Remarks
Bit
Holder 157915-9820
Bit 157915-9600 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
GE actuator
actuator on page 35).

P-VRZR- 022

[4] Regulating valve removal


Socket
Assemble the socket wrench to the
Regulating valve
wrench regulating valve and then remove the
regulating valve.
Tool name Part no Remarks
Socket wrench 157913-7000

P-VRZR- 023

- 20 -
DISASSEMBLY

Holder
[5] TCV (timing control valve) removal
(1) Remove the TCVs torx bolts.
Bit
Tool name Part no Remarks
TCV torx bolts (2)
Holder 157915-9820
Bit 157915-9600 T30

P-VRZR- 024

(2) Lift the TCV up a little and then insert a


TCV
screwdriver into the gap to pry up and
remove the TCV.
Screwdriver
Advice
Do not damage the pump housing.

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
EEPROM
sensor) and timer cover removal
(1) Remove the EEPROM.

P-VRZR- 311

- 21 -
DISASSEMBLY

(2) Remove the TPS bolts.

TPS bolts (2)


TPS

P-VRZR- 026

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

TPS standard point shim Core rod P-VRZR- 027

Torx bolts (2) (4) Remove the timer cover and the O-rings
O-ring (large)
(large and small).
Tool name Part no Remarks
Holder 157915-9820
Bit 157915-9600 T30

Timer cover

O-ring (small)
Bit Holder P-VRZR- 028

- 22 -
DISASSEMBLY

[7] CPV (constant pressure valve)


holder and plug removal
(1) Loosen the CPV holders.
Socket wrench Tool name Part no Remarks
Socket wrench 157914-3600
CPV holders (4)

P-VRZR- 029

(2) Remove the CPV holders and the gaskets.


Gaskets (4) Advice
Distributor head Line up the removed CPV holders in order
CPV holders (4) to match the positions (A, B, C, D) on the
distributor head from where they were
removed.

P-VRZR- 030

(3) Remove the plug using a hexagon wrench


(SW14mm).
Hexagon wrench

Plug

P-VRZR- 031

(4) Remove the snapring and shim from the


Snapring rotor shaft.
Distributor head
Shim Note:
The shim is easier to remove after removing the
distributor head assembly.

P-VRZR- 032

- 23 -
DISASSEMBLY

[8] Distributor head removal


Holder
(1) Remove the distributor heads torx bolts.
Bit Tool name Part no Remarks
Distributor heads torx bolts (4)
Holder 157915-9820
Bit 157915-9600 T30

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

P-VRZR- 033

Distributor head (2) Pull out the distributor head.


Advice
Do not drop the control sleeve.
(3) Remove the washer.
Control sleeve

Washer

P-VRZR- 034

Holder Torx bolts (2) [9] Forked plate and rotor shaft
Bit Rotor shaft assembly removal
Forked plate assembly (1) Remove the forked plate.
Tool name Part no Remarks
Holder 157915-9820
Bit 157915-9301 T20

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

- 24 -
DISASSEMBLY

Rollers (2) Remove the rotor shaft assembly and


Rotor shaft assembly
remove the rollers and roller shoes from the
Clip rotor shaft.
Roller shoes
Advice
Spring
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.
P-VRZR- 036
Tool name Part no Remarks
Clip 157971-0500

Advice
Do not disassemble the plunger from the
rotor shaft.

[10] Snapring removal


Insert the hooks pin into the snaprings hole
Hook
and tighten the butterfly nut to pull out the
Pin
snapring.
Snapring
Tool name Part no Remarks
Hook 157928-5820

P-VRZR- 037

[11] Drive shaft removal


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

Seal ring
Washer
P-VRZR- 038

- 25 -
DISASSEMBLY

Cam ring
[12] Cam ring removal
Position the bearing on the drive side and
remove the cam ring.
Bearing

P-VRZR- 039

Slot [13] Timer piston removal


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

EEPROM installation position P-VRZR- 040

[14] Bearing removal


Button Insert the holder into the bearing, push the
holder button and remove the bearing.
Holder
Tool name Part no Remarks
Bearing Holder 157928-3620

P-VRZR- 041

- 26 -
DISASSEMBLY

Short torx bolt [15] Feed pump removal


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

Advice
Long torx bolts (3) Use care because the torx bolt heads are
easily broken.
Note:
P-VRZR- 042 Of the four torx bolts, only the three long ones
are screwed into the feed pumps pump housing.
For feed pump Part no Remarks
149916-0400
Short torx bolt 1
(9 443 612 874)
149916-0300
Long torx bolt 3
(9 443 612 873)
(2) Remove the feed pump cover.
(3) Remove the feed pump O-ring.

Feed pump holder Chamfer (4) Position the feed pump holder chamfer
Pump housing toward the GE actuator.
(5) Push the feed pump holder into the pump
housing, aligning the holders two pins with
the feed pump holes.
Tool name Part no Remarks
Pins
Feed pump holder 157928-4320
Feed
pump

P-VRZR- 043

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

Bracket C

P-VRZR- 044

- 27 -
DISASSEMBLY

(7) Hold the feed pump holder and turn the


pump housing upside down.
Pump housing (8) Remove the feed pump holder with the feed
Feed pump pump from the bottom of the pump housing.
Advice
Remove the rotor assembly and the feed
Feed pump pump cover together with the feed pump
holder
holder.

P-VRZR- 045

(9) Position the plate on the cover and turn the


feed pump holder right side up.
Plate
Tool name Part no Remarks

Cover Plate 157928-4800

Feed pump
Advice
Always store the feed pump in the assembled
Holder
state.

P-VRZR- 046

- 28 -
COMPONENT INSPECTION

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

17

14

4
10

14 16
15

1
14
8 4
18 5

7
6

9 2
3
13
11
12

P-VRZR- 047

Repair kit part no: 149960-0020 (Bosch part no. 9 443 612 894)
Key
RBAJ part no Bosch part no Part name Qty Application
no
1 149911-0800 9 443 613 478 O-ring 1 FBB holder
2 149911-0000 9 443 612 857 O-ring 1 Feed pump
3 149912-0200 9 443 612 864 Seal ring 1 Drive shaft
4 149911-0100 9 443 612 858 O-ring 2 TPS
5 149911-0200 9 443 612 859 O-ring 1 Timer cover
6 149911-0300 9 443 612 860 O-ring 1 Timer cover
7 146600-0000 9 461 610 413 O-ring 2 Head housing
8 146433-0100 9 461 610 239 Gasket 6 CPV assembly
9 146600-0500 9 461 610 418 O-ring 1 Head plug
10 149912-0800 9 443 612 865 Seal ring 1 GE housing
11 161440-3800 9 443 610 357 O-ring 1 TCV (small)
12 161440-3700 9 443 610 356 O-ring 1 TCV (large)
13 149913-0100 9 443 612 866 Back-up ring 1 TCV
14 139512-0500 9 411 611 625 Gasket 6 In and out (t = 1.6)
15 146600-0600 9 461 610 419 O-ring 1 Regulating valve
16 146600-0700 9 461 610 420 O-ring 1 Regulating valve
17 149912-0500 9 443 612 771 Seal ring 1 Magnet valve
18 029921-4020 9 442 610 255 Cap 6 CPV holder

- 29 -
COMPONENT INSPECTION

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

Pump housing
P-VRZR- 048

(2) Replace the pump housing if the timer piston


Pump housing
cylinder is damaged or worn.
(3) If the regulating valve is blocked with dirt,
etc, clean it using compressed air. If it
cannot be cleaned, replace the pump
housing.
Advice
When replacing the pump housing, replace
it with the service kit. The service kit
contains a pump housing and a timer piston.
Timer piston cylinder Tool name Part no Remarks
P-VRZR- 049
149500-0420
Service kit
(9 443 613 486)

[2] Oil seal


Replace the oil seal if the lip is damaged or
worn.
Advice
Oil seal Refer to [3] Oil seal removal below for
the removal procedure.
Refer to [4] Oil seal installation below
for the installation procedure.
Oil seal lip
P-VRZR- 050

[3] Oil seal removal


(1) Insert the collet into the oil seal.
Tool name Part no Remarks
Collet 157928-4100 For 25 shaft dia
Oil seal
Extractor 157928-4120 For 25 shaft dia

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

- 30 -
COMPONENT INSPECTION

Press (2) Insert the bar into the collet from the pump
Bar Pushrod housing side.
(3) Hold the pushrod against the bar and push
it using a press to remove the oil seal.
Tool name Part no Remarks
Bar 157925-2800 For 25 dia shaft
Pushrod 157926-1000
Collet
Oil seal

P-VRZR- 052

Press [4] Oil seal installation


(1) Apply wax sealant (L101; manufactured by
Outer
surface
NOK) to the outside surface of a new oil seal.
Pump housing
Tool name Part no Remarks
Guide 157848-2300

(2) Pressfit the new oil seal into the pump


Oil seal
housing until it is level with the surface of
the pump housing.
Advice
P-VRZR- 053 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.
Plate (3) Replace the feed pump assembly if the rotor
Cover Rotor Liner or plate is rusted or gnawed.

P-VRZR- 054

[6] Drive shaft assembly


(1) Replace the drive shaft assembly if the drive
key or the feed pumps drive side key groove
is damaged.
(2) Replace the drive shaft assembly if the taper
is scratched or worn.
(3) Replace the drive shaft assembly if the
thread is damaged.
(4) Replace the drive shaft assembly if the shaft
Drive shaft assembly or oil seal contact surface is worn.
(5) Replace the drive shaft assembly if the
P-VRZR- 055
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 shafts 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 assemblys sliding parts
are peeling, gnawed or scorched.
Radial plungers
(2) Replace the washer with a new one if it is
worn.

Roller shoes

Washer
Rollers P-VRZR- 057

[8] Cam ring


(1) Replace the cam ring if the cam ring pin is
Cam ring worn.
(2) Replace the cam ring if there is any play
between the cam ring pin and the timer
slider.
Pin

Timer slider

P-VRZR- 058

(3) Replace the cam ring if the cam rings cam


profile is peeling or scorched.
Cam ring

P-VRZR- 059

- 32 -
COMPONENT INSPECTION

[9] Timer piston


(1) Replace the piston if the outside surface is
worn or scratched.
Timer piston (2) Replace the slider if it is worn.
Advice
When replacing the timer piston, replace it
Slider with the service kit. The service kit contains
a pump housing and a timer piston.
Tool name Part no Remarks
149500-0420
Service kit
P-VRZR- 060 (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.
Rotor shaft If the rotor shaft does not move smoothly,
replace the distributor head assembly.

Distributor head
P-VRZR- 061

(2) Inspect the plungers. If they are worn or


damaged, replace the distributor head
Radial plungers assembly.
(3) Inspect the rollers and the roller shoes.
Replace them with new ones if they are
worn, peeling, scorched or gnawed.

Roller shoes

Rollers
P-VRZR- 062

(4) Replace the distributor head assembly if


there is any play between the cam rings
plate and the links pin.

Links pin

Plate

P-VRZR- 063

- 33 -
COMPONENT INSPECTION

(5) Assemble the GE actuators ball pin to the


control sleeve groove. If there is any play,
GE actuators ball pin
replace the distributor head assembly.

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
Regulating valve
piston inside the regulating valve is sticking.
Advice
Always replace the O-rings with new
ones.
O-rings Do not disassemble the regulating valve
unless necessary.
Stopper

P-VRZR- 067

- 34 -
COMPONENT INSPECTION

[14] Magnet valve


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.
O-ring Advice
Spring
Always replace the O-ring with a new one.
(3) Check the magnet valve resistance and
Armature replace the magnet valve assembly if the
resistance is not as specified.
Gauze filter
P-VRZR- 068 Terminal Resistance Ambient temperature
nos ( ) (C)
1 - GND 8.01.2 235
GE actuator
Ball pin (4) Clean the gauze filter.
[15] GE actuator
(1) Replace the GE actuator if the ball pin is
worn or if the plating is damaged or peeling.

P-VRZR- 069

(2) Assemble the GE actuators ball pin in the


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

Control sleeve

GE actuator terminals (reference)


P-VRZR- 070
Terminal no. Name Remarks
1 FCV Black, magnet valve
2 Blank -
3 Blank -
12
6 4 CSP (OSC) Yellow
11
5 5 TCV (+) Red
10
4 6 GE (+) White
3 7 TF (+) Blue, fuel temperature (+)
2 9 8 CSP (MDL) Red
8 9 TCV (-) Black
1
7 10 GE (-) Green
11 TF (-) Grey, fuel temperature (-)
P-VRZR- 312 12 CSP (GND) Black

- 35 -
COMPONENT INSPECTION

(3) Measure the resistances between each of


the terminals.
6
Reference values:
12
5 11 Terminal Resistance Ambient temperature
4 10
nos ( ) (C)
6 - 10 0.710.25 235
3 9 8 - 12 5.90.3 235
2 8
4-8 5.90.3 235
1 7
4 - 12 11.80.6 235
7 - 11 2.00.6k 235

P-VRZR- 313

[16] TCV (timing control valve)


(1) Replace the TCV if the TCV or O-ring is
TCV scratched or worn.
(2) Check the filter for dirt. If it is dirty, clean it
using compressed air.
Advice
Do not twist or break the O-ring or backup
ring.

Filter

P-VRZR- 073

(3) Measure TCV resistance.


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

TCV

P-VRZR- 074

[17] TPS (timer piston sensor)


(1) Replace the TPS if the inside of the TPS or
TPS Timer spring the core rod is bent or damaged.
(2) Replace the TPS is the timer spring is worn
4
1 or the seats are not centered.
(3) Measure TPS resistances.
Reference values:
5 2 Terminal Resistance Ambient temperature
3
nos ( ) (C)
6
Core rod 1-3 82.05.7 2510
2-3 82.05.7 2510
P-VRZR- 075

- 36 -
COMPONENT INSPECTION

[18] Np sensors
Np sensors
1 Measure the Np sensors resistances.
Terminal nos Resistance ( ) Remarks
(-)
2-3 2.15k Main
2 (-)
2-3 2.15k Backup
3 (+)
(+)
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.
P-VRZR- 314 3 terminal.

(k) [19] Fuel temperature sensor


Measure fuel temperature sensor
resistances.
See page 35 for GE actuator terminals.
Resistance

Reference values:
(25, 2) = (fuel temperature, resistance) Terminal Resistance
Fuel temperature (C)
nos ()
7-8 2 25

Fuel temperature (C) P-VRZR- 163

- 37 -
GEAR REASSEMBLY

DRIVE GEAR
CAUTION
Individual parts of the main gear (key nos. 1/1 to 1/8) cannot be replaced. [This is because
the pin (1/6) is pressfitted through the sub-gear (1/2) to the main gear (1/1), and disassembly
is not possible once the drive gear has been assembled.] The pulse plate (key no. 2),
however, can be reused or replaced.
The drive gear is not assembled when supplied. The following describes the assembly
procedure.

1/6 1/8

1/5

1/3
1/2

1/4

1/1
3 2
P-VRZR- 327

Key
RBAJ part no Bosch part no Part name Qty
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

Pin
(1) Fully pressfit the pin to the main gear.
Part no
Main gear Part name Remarks
(Mitsubishi part no)
149931-1300
Pin
(ME204193)
149931-1910
Main gear
(ME204369X)
Pin

P-VRZR- 328

- 38 -
GEAR REASSEMBLY

Pin
(2) Fully pressfit the pin to the sub-gear.
Advice
Sub-gear
Pressfit the pin to the face of the gear without
Pin the mark A.
Part no
Part name Remarks
(Mitsubishi part no)
149931-1300
Pin
(ME204193)
149931-2000
Sub-gear
(ME204370)
Back is stamped A P-VRZR- 329

Racks (2) Base Socket head bolts (2) (3) Fix the base in a vise.
(4) Install the racks to the base using the socket
head bolts.
Tool name Part no Remarks
The racks are
Base 157924-8520 included with the
Hexagon wrench
base.
(SW5) Use the racks with
Rack 157917-4300 the '4M41'
stamping.
P-VRZR- 330

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

P-VRZR- 331

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


Part no
Main gear Part name Remarks
(Mitsubishi part no)
Spring
149931-1200
Spring
Pin (ME204192)

P-VRZR- 332

- 39 -
GEAR REASSEMBLY

Sub-gear (7) Attach the sub-gear to the main gear. At


this time, hook the sub-gears pin to the
spring.
Spring

Pin

P-VRZR- 333

Wrench (8) Align the wrench with the sub-gears holes


and attach it to the sub-gear.
Tool name Part no Remarks
Sub-gear
Wrench 157917-4920

P-VRZR- 334

Socket head bolt (9) Turn the wrench counterclockwise to align


Wrench
the main gears teeth with the sub-gears
teeth.
Sub-gear
(10) Screw in the socket head bolt (SW5) to
tighten the sub-gear to the main gear.
Specified torque: 9 ~ 13 Nm
{0.9 ~ 1.3 kgfm}
Part no
Part name Remarks
(Mitsubishi part no)
149917-1500
Socket head bolt SW5
(ME204287)
P-VRZR- 335

CAUTION
Pliers
Snapring Socket head bolts cannot be reused.
Main gear

(11) Hold the snapring open using pliers and


install it in the main gears snapring groove.
Tool name Part no Remarks
Pliers 157928-4400

Part no
Part name Remarks
(Mitsubishi part no)
149931-1600
Base Snapring
P-VRZR- 336 (ME204236)

- 40 -
GEAR REASSEMBLY

(12) Remove the drive gear assembly from the


base and pressfit the pin until it is level
Sub-gear
with the face of the sub-gear.
Pin
Specified position: 0 ~ 1 mm from face of
Drive gear assembly sub-gear
Part no
Part name Remarks
(Mitsubishi part no)
149931-1400
Pin
(MF472404)

P-VRZR- 337

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

Base P-VRZR- 338

Long pulse plate hole


(14) Align the pulse plates long hole with the
Pulse plate
drive gears positioning pin and attach it
to the drive gear.
Positioning pin
Part no
Part name Remarks
(Mitsubishi part no)
149931-0600
Pulse plate
(ME203076)

Base P-VRZR- 339


(15) Screw in the bolts (SW7) and tighten the
Bolts (4) pulse plate to the drive gear.
Pulse plate Specified torque: 4 ~ 5 Nm
Drive gear
{0.4 ~ 0.5 kgfm}
Part no
Part name Remarks
(Mitsubishi part no)
149917-1400 4; not
Bolts
(MF472404) 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


Liner is basically the reverse of the disassembly
procedure. The following describes the standard
Blade Stamping
reassembly procedure.
Always replace gaskets and O-rings with new
ones.
1. REASSEMBLY
[1] Feed pump assembly reassembly
Advice
Rotor Confirm that the blades grooves are
P-VRZR- 077
positioned toward the inside.
Blade and rotor orientation cannot be
changed.
The feed pumps liner is marked with an
R for clockwise injection pump rotation
or an L for counterclockwise injection
pump rotation. Install the liner so that
the applicable mark can be seen when
the liner is viewed from the head side.

Pins Cover
(1) Position the feed pump assembly and the
cover on the feed pump holder. Assemble
the holder pins in the feed pump holes (2).
Tool name Part no Remarks
Notch Feed pump holder 157928-4320
Chamfer
Advice
Align the feed pump cover notch with the
Feed pump holder
feed pump holder chamfer.
Notch 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
Notch
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
Pump housing down.

Feed pump holder

P-VRZR- 079

- 42 -
REASSEMBLY

(4) Attach the pump housing to bracket C and


Pump housing
remove the feed pump holder.

Bolts (3)

Bracket C
P-VRZR- 080

Set screw (5) Screw the set screw into the pump housing.
(The set screw is used as a guide when
positioning the feed pump cover.)
Tool name Part no Remarks
Set screw 157928-4500

(6) Assemble the feed pump O-ring to the feed


pump. (Refer to page 29 for the O-ring key
Feed pump number.)

P-VRZR- 081

Set screw Guide (7) Align the feed pump cover hole with the set
screw and assemble the cover to the feed
pump.
(8) Insert the guide into the feed pump.
Tool name Part no Remarks
Guide 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


Holder two torx bolts.
(11) Tighten the four torx bolts uniformly. (One
Bit
of the four torx bolts does not screw into
the pump housing.)
Specified torque: 3.0 ~ 4.0 Nm
{0.3 ~ 0.4 kgfm}
For feed pump Part no Remarks
149916-0400
Short torx bolt 1
(9 443 612 874)
P-VRZR- 083 149916-0300
Long torx bolt 3
(9 443 612 873)

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.
Seal ring Advice
Be careful with the assembly orientation of
the seal ring and ensure it is securely
assembled to the feed pump cover.

Feed pump Head


side side

P-VRZR- 084

[2] Bearing reassembly


Button
Holder (1) Assemble the holder to the bearing and
press the holder button (to hold the bearing).
Bearing
(2) Install the bearing in the pump housing.
Pump housing Tool name Part no Remarks
Holder 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

Timers low pressure side (2) Assemble the timer piston and slider in the
Pump housing
Slider hole pump housing.
Advice
Align the slider hole with the timer piston
hole.
Timer piston
The slider is assembled in the timer with
the hole positioned toward the GE
actuator side.
Note:
The timer pistons low pressure side is
positioned toward where the Q adjustment ROM
Timers low pressure side P-VRZR- 087
is installed.
Cam ring [4] Cam ring reassembly
Assemble the cam ring in the pump housing.
At this time, insert the cam ring pin into the
timer pistons slider hole.
Cam ring pin
Advice
Confirm that the timer piston slides
smoothly.

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 Part no Remarks

Holder
Holder 157928-3620
P-VRZR- 089

Spacer Feed pump cover (3) Insert the spacer into the pump housing.
Spacer
Tool name Part no Remarks
Spacer 157928-4700
U-shaped
ring

Bearing

Pump housing P-VRZR- 090

(4) Assemble the shim and the feed pumps


Shim
drive side key on the drive shaft.
Key (5) Assemble the oil seal guide on the drive
shaft thread.
Tool name Part no Remarks
For 25 dia
Oil seal guide 157928-4000
shaft

Drive 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).
Drive shaft (7) Align the drive shaft key with the feed pump
rotor key groove and insert the drive shaft
into the feed pump.
Advice
Insert the drive shaft gently into the feed
pump while turning it clockwise and counter
clockwise to align the key with the key
groove.
P-VRZR- 092

- 46 -
REASSEMBLY

Plastic hammer (8) Lightly tap the drive shaft using a plastic

;;
Drive shaft hammer to assemble the drive shaft with the
end fully protruding from the drive side.
1 ~ 2 mm Advice
When tapping the drive shaft with the
plastic hammer, ensure no burrs or dirt
remain on the shaft.
Inner cam 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).
P-VRZR- 093
After assembling the drive shaft, confirm
that the shaft rotates smoothly.

Spacer
[6] Snapring reassembly
(1) Remove the spacer from the pump housing.
Pump housing Advice
Confirm that the drive shafts snapring
groove can be seen through the housing
window.

P-VRZR- 094

(2) Assemble the snapring to the clip.


Tool name Part no Remarks
Clip 157928-3120

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

Convex face

P-VRZR- 095

(3) Position the snapring in the drive shafts ring


groove and push it straight down.
Clip (4) Remove the clip from the snapring and use
Drive shafts snapring groove the end of the clip to push the snapring fully
Snapring
into the groove.
Advice
Confirm that the snapring is fully inserted
into the groove and that the drive shaft can
be rotated.

P-VRZR- 096

- 47 -
REASSEMBLY

Distributor head
[7] Adjusting drive shaft axial play
(1) Position the distributor head on the pump
housing.
Advice
Pump housing Do not assemble the O-ring or the control
sleeve at this time.

P-VRZR- 097

(2) Install and tighten two diametrically opposed


torx bolts of the four to install the distributor
Holder head.
Specified torque: 10.0 ~ 14.0 Nm
Bit {1.0 ~ 1.4 kgfm}
Torx bolts (2) Tool name Part no Remarks
Holder 157915-9820
Bit 157915-9600 T30

P-VRZR- 098

(3) Attach the measuring device to the drive


Measuring device
shaft.
Dial gauge (4) Attach the dial gauge to the measuring
device.
Tool name Part no Remarks
Measuring device 105782-4530

Drive shaft P-VRZR- 099

Measuring device (5) Measure the drive shafts axial play.


Specified value: 0.10.05 mm
(with the head assembly installed)
(6) If not as specified, select shims from the
table on the following page and exchange
the shims until the axial play is as specified.
(Refer to page 49.)
Advice
If the axial play varies greatly from the
specified value, repeat procedure [5] on page
Drive shaft P-VRZR- 100 46 and [6] on page 47.

- 48 -
REASSEMBLY

Shims
RBAJ part no Bosch part no Thickness (mm)
149602-0000 9 443 612 809 1.90
149602-0100 9 443 612 810 1.95
149602-0200 9 443 612 811 2.00
149602-0300 9 443 612 812 2.05
149602-0400 9 443 612 813 2.10
149602-0500 9 443 612 814 2.15
149602-0600 9 443 612 815 2.20
149602-0700 9 443 612 816 2.25
149602-0800 9 443 612 817 2.30
149602-0900 9 443 612 818 2.35
149602-1000 9 443 612 819 2.40

(7) Remove the dial gauge.


Measuring device (8) Remove the measuring device handle and
attach the extractor.
(9) Screw in the extractor to remove the
measuring device.
Tool name Part no Remarks
Extractor 157926-2421

Extractor
P-VRZR- 101

(10) Remove the torx bolts from the distributor


Distributor head
head.
(11) Remove the distributor head from the
pump housing.
Pump housing

P-VRZR- 102

Rotor shaft
[8] Selecting the rotor shaft shim
Distributor head Purpose
The rotor shafts axial play is measured and then
the play is adjusted to the specified value using
the shim.

Procedure 1 Adjusting the dial gauges 0


point
(1) Insert the rotor shaft into the distributor head.
(2) Install the snapring in the rotor shafts
Snapring snapring groove.
P-VRZR- 103
Advice
Do not assemble the shim at this time.

- 49 -
REASSEMBLY

(3) Attach the adapter to the head and then


Head attach the measuring device to the adapter.
Tool name Part no Remarks
Measuring device
Adapter 157845-8900
Measuring For measuring
157829-3520
device VE cam lift

Rotor shaft Adapter

P-VRZR- 104

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

Measuring device

Rotor shaft
Dial gauge
Adapter

P-VRZR- 105

Procedure 2 Calculating the shim


Head thickness
(1) Push the rotor shaft fully to the right and
Measuring device measure the full stroke from the dial gauge.
Advice
The rotor shafts groove must not catch on
the head.

Rotor shaft Adapter

P-VRZR- 106

Rotor shaft
(2) Select a shim using the formula below.
Distributor head Shim thickness = full stroke 0.2 (mm)
RBAJ part no Thickness
Bosch part no
(key no. 53) (mm)
149720-0000 9 443 612 851 2.1
149720-0100 9 443 612 852 2.2
149720-0200 9 443 612 853 2.3
149720-0300 9 443 612 854 2.4
(3) Install the selected shim and the snapring
to the rotor shaft.
Shim Snapring (4) After inserting the shim, confirm that the
P-VRZR- 107
stroke is as specified. If not as specified,
repeat Procedure 1 and Procedure 2.
Specified stroke: 0.20.1 mm
- 50 -
REASSEMBLY

(5) Remove the dial gauge and adapter from


the head.
(6) Remove the snapring.

TPS standard point shim [9] TPS and timer cover reassembly
Pump housing
Adjusting shim (1) Assemble the TPS to the pump housing.
Specified torque: 7.0 ~ 10.0 Nm
Core rod {0.7 ~ 1.0 kgfm}
Advice
Do not mistake the positions of the TPS
standard point shim and the adjusting shim.
TPS

P-VRZR- 108

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


Pump housing then assemble the high pressure side timer
Timer cover
cover on the pump housing.
Specified torque: 7.0 ~ 10.0 Nm
{0.7 ~ 1.0 kgfm}

P-VRZR- 109

[10] Pump removal


Remove the pump housing from bracket C.

Pump housing

Bracket C
P-VRZR- 110

- 51 -
REASSEMBLY

2. PRE-STROKE ADJUSTMENT

Cam ring Link plate

Pre-stroke adjustment values

Cam lift (mm)


Timing link shaft ball pin

Original pre-stroke
Control sleeve

Angle of cam rotation ()

Beginning of Beginning of pressure


Cam link pin cam lift delivery

VRZ pre-stroke (substitute)


Timer piston Timing link shaft
P-VRZC- 034 P-VRZR- 315

Fundamentally, pre-stroke is the amount of lift from the cams bottom dead center position to the
beginning of pressure delivery position. With the VRZ pump, however, because it is not possible
to measure the cam lift with the pump assembled, the cam angle is instead measured from the
beginning of cam lift position to the beginning of pressure delivery position.
The beginning of pressure delivery position can be changed by changing the phase (ie, the angle)
between the cam link and the control sleeve, which are connected by the timing link shaft.
Consequently, by changing the position of the link plate groove, we can change the phase of the
cam link and the control sleeve to adjust the pre-stroke (ie, substituting the angle instead).

Pre-stroke adjustment sequence


(1) Attach the measuring device to the pump.
(2) Align the measuring devices measuring terminal with the standard cylinder Bs cam position.
(3) Find the cams bottom dead center position using the dial gauge, then zero the dial gauge.
(4) Rotate the pump in the specified direction of rotation and set the cam lift to 0.70 mm using the
dial gauge.
(5) Set the 0 point using the KMA device to display cam lift as an angle.
(6) Turn the pump back 10 in the direction opposite to the specified direction of rotation. Turn the
pump 5 in the specified direction of rotation (to prevent backlash).
(7) Confirm that the dial gauge displays 0 mm.
(8) Using the KMA device, reset the 0 point. (Using the KMA device, begin cam lift.)

- 52 -
REASSEMBLY

Injection pump Flange [1] Measuring device installation


CAUTION
The pump test bench drive motor must be
turned OFF.
Injury or damage may result if the pump test
bench drive motor is turned ON.
(1) Temporarily attach the fixing stand to the
pump test bench and attach the injection
pump to the fixing stand.
Fixing stand P-VRZR- 316 Tool name Part no Remarks
Fixing stand 105796-0000 For 20NP
Flange 157811-9020 For VRZ

(2) Align the key groove with the standard


cylinder Bs pressure delivery cam position
as shown at left.

Drive shaft key position


for 4M41 model engine

P-VRZR- 111

(3) Align the drive shaft key groove and the


measuring devices measuring terminal.
Measuring terminal
Note:
The pre-stroke can be measured on any
cylinder. Because the pump is set at the
Drive shaft key groove standard cylinder B, however, measure the
pre-stroke for this cylinder.
If the drive shaft key groove and the
measuring devices measuring terminal are
not aligned, pre-stroke cannot be adjusted
Measuring device from cylinder B when the rotor shaft is
P-VRZR- 317
assembled.
Measuring device Existing bolts (2) Drive shaft (4) Install the pre-stroke measuring device.
Specified torque: 10.0 ~ 14.0 Nm
{1.0 ~ 1.4 kgfm}
Tool name Part no Remarks
Measuring device 105782-4540

Advice
Assembly position Align the drive shafts key groove and the
of measuring
devices measuring
measuring devices measuring terminal
terminal with the drive shaft.
P-VRZR- 112 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


Coupling
the coupling with the key, assemble it to the
Fixing stand
drive shaft and then fix it using the nut.
Tool name Part no Remarks
Coupling 157847-0820 Shaft dia 25
Specified torque: 167 ~ 185 Nm
{17.0 ~ 19.0 kgfm}

P-VRZR- 114

(6) Move the fixing stand to assemble the


Test bench drive coupling
coupling teeth to the pump test bench drive
coupling.
Advice
Ensure approximately 1 mm axial clearance
between the coupling and the drive coupling.

Fixing stand

P-VRZR- 115

Flywheel
(7) Securely tighten the fixing stand installation
bolts and nuts and the drive coupling socket
head bolt to fix the injection pump to the
pump test bench.
(8) Turn the pump test bench flywheel using the
lever to confirm that the injection pump
rotates smoothly.
CAUTION
Remove the lever after operating the
Lever flywheel.
P-VRZR- 116 Operating the test bench without removing
the lever can cause serious injury and
damage the test bench.

- 54 -
REASSEMBLY

Monitor display example [2] Setting the 0 point for pre-stroke


1 2 3 4 5
angle measurement
6 7 8 9 10 11 12
adjustment
(1) Turn the pump test benchs main switch ON
and set the KMA (continuous measuring
device) as described below. [Refer to the
KMA (continuous measuring device
operation manual): Publication No EC18E-
11091.]

Select the angle measurement display


Press F6 Select Settings
Press Enter Set the direction of rotation
F1 F2 F3 F4 F5 F6 F7 F8 Press F2 F2
P-VRZR- 164

Flywheel (2) Turn the pump test bench flywheel in the


direction of pump rotation to find the
standard cylinders bottom dead center
position on the measuring device dial gauge.
(Refer to the data sheet for the standard
cylinder.)

Dial gauge P-VRZR- 118

(3) Zero the dial gauge.


(4) Turn the flywheel in the direction of rotation
so that the dial gauge reading is 0.7 mm.

Dial gauge

P-VRZR- 117

- 55 -
REASSEMBLY

Monitor display example (5) Set the continuous measuring device as


angle measurement
described below.
1 5 3 6 2 4 Press F2 Press both shift keys (press both
0.0
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
F1 F2 F3 F4 F5 F6 F7 F8 measurement display at 355 (ie, turn the
P-VRZR- 165
flywheel back 5).
(7) Check that the dial gauge reading is 0mm.
(8) Set the continuous measuring device as
Flywheel
described below.
Press F6 Select zero point setting
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

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

TPS

Timer cover

P-VRZR- 121

[3] Component reassembly


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

Forked plate Replaced Replaced Replaced


Not
Replaced Replaced
replaced
Holder Bit
Not replaced Replaced Replaced
P-VRZR- 122
Not Do not replace (use the
Not replaced
Drive shaft
replaced installed forked plate)*
Rotor shaft pin
Spring
*If the installed forked plate fork is worn,
assemble a forked plate marked G.
(Refer to the table on page 67.)
Specified torque: 3.0 ~ 5.0 Nm
{0.3 ~ 0.5 kgfm}
Clip Tool name Part no Remarks
Rotor shaft
Holder 157915-9820
Rotor shaft assembly
Bit 157915-9301 T20

P-VRZR- 123
(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 Part no Remarks
Clip 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


Control sleeve (1) Assemble the O-ring on the distributor head.
(2) Assemble the control sleeve in the
distributor head.
Head side
Advice
The face with the larger chamfer is
Large chamfer Small chamfer positioned toward the head.

Distributor head

P-VRZR- 124

O-rings (2) (3) Assemble the distributor head assembly to


Distributor head 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
Pump housing P-VRZR- 125
plate groove with the distributor head
assembly pin.
(6) Move the timer piston and confirm that the
Torx bolts
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
Distributor head 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
Pump housing P-VRZR- 126
be damaged.
(8) Tighten the torx bolts until the distributor
head assembly is securely tightened to the
pump housing.

- 58 -
REASSEMBLY

(9) Install the other two torx bolts and then


tighten all four torx bolts to the specified
torque.
Specified torque: 10.0 ~ 14.0 Nm
Torx bolts (4) {1.0 ~ 1.4 kgfm}
Tool name Part no Remarks
Holder
Holder 157915-9820

Bit Bit 157915-9600 T30

P-VRZR- 127

(10) Assemble the shim and snapring to the


rotor shaft.
(11) Install the plug to the distributor head
Snapring
together with a new O-ring.
O-ring

Shim
Plug
P-VRZR- 128

(12) Tighten the plug using a hexagon wrench


(SW14mm).
Plug Specified torque: 20.0 ~ 29.0 Nm
Hexagon wrench {2.0 ~ 3.0 kgfm}

P-VRZR- 129

(3) CPV holder reassembly


(1) Assemble the gaskets and CPV holders to
Dummy holder the distributor heads cylinders A, C and D.
Cylinder B 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
Gaskets (4)
the distributor heads cylinder B.
CPV holders (3)
Tool name Part no Remarks
Distributor head P-VRZR- 130 Part of pipe assembly
Holder 157845-9500
157845-9520.

- 59 -
REASSEMBLY

CPV holder (3) Tighten the CPV holders using a socket


Socket wrench wrench.
Specified torque: 44.0 ~ 54.0 Nm
{4.5 ~ 5.5 kgfm}
Tool name Part no Remarks
Socket wrench 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

Pump housing (3) Push the TCV into the pump housing using
your finger and fix it using the torx bolts.
Specified torque: 7 ~ 10.0 Nm
{0.7 ~ 1.0 kgfm}
Tool name Part no Remarks
TCV
Holder 157915-9820
Bit 157915-9600 T30
Holder

Bit Torx bolts (2) P-VRZR- 134

- 60 -
REASSEMBLY

(5) Timer cover and TPS (timer piston


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

Small O-ring Ti m e r
cover
Large O-ring P-VRZR- 135

Small O-ring Pump housing (2) Push the small O-ring securely into the pump
Large O-ring housing using your finger.
(3) Push the large O-ring securely into the timer
cover using your finger and install the timer
cover using the torx bolts.
Specified torque: 7.0 ~ 10.0 Nm
Ti m e r
{0.7 ~ 1.0 kgfm}
Torx bolts (2) cover
Tool name Part no Remarks
Bit
Holder 157915-9820
Holder
Bit 157915-9600 T30
P-VRZR- 136

TPS O-ring (4) Assemble the TPS standard point shim, the
core rod, the timer spring and the timer
Timer stroke
stroke adjusting shim in the pump housing.
adjusting shim 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.
Timer spring Advice
Core rod Ensure the O-rings are not damaged.
Standard point shim
Pump housing P-VRZR- 137

(6) Secure the TPS to the pump housing using


Pump housing the torx bolts and a socket wrench (M6).
TPS
Specified torque: 7.0 ~ 10.0 Nm
{0.7 ~ 1.0 kgfm}

Socket wrench

Torx bolts (2)

P-VRZR- 138

- 61 -
REASSEMBLY

Regulating valve
(6) Regulating valve installation
Pump housing
(1) Shake the regulating valve and confirm that
the piston is moving (listen for a clicking
sound).
(2) Install the regulating valve in the pump
housing.
Advice
Confirm that the regulating valve piston
moves smoothly.

P-VRZR- 139

(3) Tighten the regulating valve using the socket


Socket wrench
wrench.
Specified torque: 10.0 ~ 13.0 Nm
{1.0 ~ 1.3 kgfm}
Tool name Part no Remarks
Socket wrench 157913-7000

P-VRZR- 140

(7) GE actuator installation


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

P-VRZR- 141

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

Rotor shaft
P-VRZR- 142

- 62 -
REASSEMBLY

GE actuator pin (3) Assemble the GE actuator pin in the control


sleeve groove.

P-VRZR- 143

GE actuator (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
P-VRZR- 144
the groove.
GE actuator (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.

P-VRZR- 145

Holder Torx bolts (6) (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.
Bit
Specified torque: 7.0 ~ 10.0 Nm
{0.7 ~ 1.0 kgfm}
Tool name Part no Remarks
Holder 157915-9820
Pump housing P-VRZR- 146 Bit 157915-9600 T30

- 63 -
REASSEMBLY

Magnet valve assembly (8) Magnet valve assembly installation


GE actuator (1) Install the magnet valve assembly to the GE
Magnet valve
actuator.
O-ring Advice
Spring Ensure the filter is installed securely.

Armature

Gauze filter
P-VRZR- 147

(2) Tighten the magnet valve assembly using a


Magnet valve assembly
torque spanner.
Spanner
Specified torque: 20.0 ~ 25.0 Nm
{2.0 ~ 2.5 kgfm}

P-VRZR- 148

(9) Pre-stroke adjustment


(1) Connect the fuel hose to the injection pump
Gaskets (2)
using the adapter.
Adapter Tool name Part no Remarks

Injection pump
Adapter 157977-8000
Gasket 026512-1640

Hose
P-VRZR- 149

(2) Install plugs to where the distributor head


and GE actuator overflow valves were
Plugs removed.
Advice
Install any suitable plugs to maintain pump
chamber air tightness.

P-VRZR- 150

- 64 -
REASSEMBLY

(3) Remove cylinder Bs delivery valve holder


Pipe assembly and assemble the pipe assembly to cylinder
B.
Tool name Part no Remarks
Cylinder B Pipe assembly 157845-9520

P-VRZR- 151

(4) Connect the direct current harness to the


Magnet valve assembly
magnet valve.
Direct current harness Advice
Magnet valve supply voltage
12V specification: 12V

P-VRZR- 152

Injection pump
(5) Turn the pump test bench drive switch ON.
(6) Supply test oil to the injection pump at the
specified pressure (20.0 kPa {0.2 kgf/cm2}).
Advice
Leave the drive switch ON. Do not turn the
drive switch OFF until pre-stroke adjustment
has been completed.

P-VRZR- 153

(7) Turn the pump test bench flywheel about


Flywheel one turn in the specified direction of rotation
using the lever and use the angle
measurement display to confirm that it turns
smoothly.

Lever

P-VRZR- 154

- 65 -
REASSEMBLY

(8) Turn the pump test bench flywheel using the


Pipe assembly lever and set the pump test bench angle
measurement at the 0 position (ie, the
beginning of cam lift position).
Advice
Confirm that test oil flows from the pipe
assemblys overflow.
Align the flywheel with the position set
during Procedure [2] Setting the 0 point
for pre-stroke adjustment on page 55.
P-VRZR- 155

(9) Turn the pump test bench flywheel slowly in


the specified direction of rotation using the
Pipe assembly lever and read the angle measurement
indication (ie, the pre-stroke) when test oil
stops flowing from the pipe assembly
overflow.
Note:
Test oil has stopped flowing when only 2 ~ 3
drops / second flow from the overflow.
CAUTION
P-VRZR- 156 Remove the lever after operating the
flywheel.
Operating the test bench without removing
the lever can cause serious injury and
damage the test bench.
Advice
Leave the drive switch ON. If the drive switch
is turned OFF, angle measurement will stop.
Stop test oil flow to the injection pump by
turning the test oil cock OFF.
(10) If the pre-stroke is not as specified, replace
the forked plate and readjust. (Refer to
Cam ring
the next page for forked plate
specifications. Refer to page 57 for the
replacement procedure.)
Forked plate Specified value: 2.50.5
Advice
For clockwise rotation, if the value is larger
than specified, select plates starting from A.
If smaller, select plates working back from
M.
P-VRZR- 157
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


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

Cylinder B

P-VRZR- 158

Plugs
(12) Tighten the CPV holder using a socket
wrench.
Specified torque: 44.0 ~ 54.0 Nm
{4.5 ~ 5.5 kgfm}
Tool name Part no Remarks
Socket wrench 157914-3600

CPV holder (13) Remove the plugs.

Socket wrench P-VRZR- 159

- 67 -
ADJUSTMENT

1. ADJUSTMENT CONDITIONS
[1] Test equipment
(1) Pump test bench EPS815
(2) KMA802
(3) Oil cooler (1 687 010 130)
(4) Adjustment software operating environment
Windows 2000 PRO (at least Service Pack 2.0) English language version;
Windows OS
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

At least 2 communication ports (2 necessary for controller assembly)


Additional devices
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
Nozzle and nozzle holder assembly (1 688 901 035) Tubes
Cooling unit

Injection tubes

Joint assembly (157641-6820)


Injection pipes (157808-4720) P-VRZR- 390

- 68 -
ADJUSTMENT

(2) Fuel piping


Key no 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

1/5 1/4
1/1 1/2 1/3
1/6 1/2
Multi-way cock
1/5

1/7
Test oil hose

Pump chamber pressure


Temperature sensor cable measurement hose
P-VRZR- 391

- 69 -
ADJUSTMENT

[3] Wiring outline


(1) Controller assembly wiring
Injection pump

Tool connection 232C cable


Connection: cross connection (2 pin, 3 pin cross)
(157966-4720)

Tool connection 232C cable


Connection: straight connection
(157966-4620)

Intermediate harness
Personal computer
(157966-2421) Intermediate harness
(157966-5720)
Dsub 9 pin

FCV GND harness


Dsub 25 pin
(157966-4820)

Dsub 7 pin

ROM harness
(157966-5020)

Dsub 9 pin
To AC100V - AC120V or
AC200V - 240V power source VRZ and COVEC-F Main harness Earth to injection pump
(157966-4420 or 157966-4520) controller unit (157966-4920) or pump test bench P-VRZR- 392

(2) Wiring connections inside controller unit

PC

COM2 COM1

RS232C RS232C
COM2 COM2
VRZ & COVEC-F (ROM) CONTROLLER 25 pin 9 pin

AC ROM
100 - 120V ROM writer ROM
cable
200 - 240V

ROM
lamp
ECU
AC lamp 4D56 Injection
socket (COVEC-F) Main pump
DC 5V cable
Constant ECU
power supply
FCV switch FCV line
GE
CSP
Main power DC 24V TPS
switch Constant ECU
power supply lamp 4M41 TCV
(VRZ) Main
cable TF
ECU
DC 12V FCV
Constant FCV switch FCV line
power supply FCV line Main
cable
1
0 2 FCV
Power switch
lamp Sub-switch ECU
3 lamp WL
(COVEC-F)
ECU
Selector 4
switch

P-VRZR- 395

- 70 -
ADJUSTMENT

[4] Related materials


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

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

- 71 -
ADJUSTMENT

2. CONTROLLER UNIT CONTROLS


[1] Front panel
7 8 9 11 10 12

4 1 5 2 6 3 13 14
P-VRZR- 344

Key
Name Use and purpose
no
Pump side wire harness For connecting harness for injection pump's harness connectors and GE
1
connection controller.
Pump side wire harness For connecting harness for injection pump's harness connectors and GE
2
connection controller.
Pump side wire harness For connecting harness for injection pump's harness connectors and GE
3
connection controller.
FCV (magnet valve) ON / OFF Turns the FC V (magnet valve) ON and OFF. Turned ON when i n use
4
switch (positioned up). Usually turned OFF (positioned down).
FCV (magnet valve) ON / OFF Turns the FC V (magnet valve) ON and OFF. Turned ON when i n use
5
switch (positioned up). Usually turned OFF (positioned down).
FCV (magnet valve) ON / OFF Turns the FC V (magnet valve) ON and OFF. Turned ON when i n use
6
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.

Orange lamp lights when ECU in use


10 Power pilot lamp
(when breaker is turned ON).

- 72 -
ADJUSTMENT

Key
Name Use and purpose
no
Turn to align with ECU in use.
0: All OFF
1: No. 1 ECU
11 ECU changeover switch
2: No. 2 ECU
3: No. 3 ECU
4: Spare ECU
Power sub-switch for controller unit for VRZ adjustment. Press once to turn ON.
12 Sub-switch
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.

ROM wire harness connecting For connecting injection pump's ROM harness connector to ROM controller
14
terminal using wire harness.

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

Advice
Do not use the controller unit with oily hands. The oil may stick to the dials and cause
improper resistor contact inside the controller unit, preventing proper operation.
Before turning the power switch ON, confirm that the wire harnesses are properly
connected.

- 73 -
ADJUSTMENT

[2] Rear panel

CE

P-VRZR- 345

Key
Name Use and purpose
no
AC100V - 120V power or Connect to AC100V - 120V, 50/60Hz power source or
1
AC 200V - 240V power terminal AC 200V - 240V power source, 50/60Hz.
Controller unit power switch.
2 Main switch (breaker)
Turn ON when in use (position at 'I'). Position at 'O' to turn OFF.
D-sub 9 pin cable connection
3 Connects RS232C cable to personal computer (for GE).
(COM1)
D-sub 25 pin cable connection
4 Connects RS232C cable to personal computer (for Q-ROM)
(COM2)

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

Advice
Do not use the controller unit with oily hands. The oil may stick to the dials and cause
improper resistor contact inside the controller unit, preventing proper operation.
Before turning the power switch ON, confirm that the wire harnesses are properly
connected.

- 74 -
3. PUMP ADJUSTMENT TOOL FLOW CHART
1. Password input

Disagreement

Agreement
2. ECU selection
[1] 4D56
[2] 4M41
[3] WL
[4] Manual operation
[5] Workshop name registration
[6] Exit

[1] or [2] or [3] [4] [5] [6]


Part no. input Manual operation Workshop name registration Exit
[1] Adjustment
[2] Inspection
Input item Confirmation
[1] Workshop name
[2] Address
- 75 -

Pre-check 1.
[3] Telephone Program completed
[4] Fax
[5] Operator's name
[6] Password
Adjustment Inspection
Step 1-XX Adjustment Step 1-XX Inspection
Select "Registration" button
StepXX + 1 ROM compensation

StepXX + 2 ROM writing


Confirmation
Repeat OK Repeat
measurement measurement OK
Adjustment result Inspection result
Push [MENU] button Cancel
(= Registration change Push [MENU] button

ADJUSTMENT
completed) (= Item is not changed)
Print result Cancel Print result Cancel

OK
P-VRZR- 396

Final confirmation Final confirmation


ADJUSTMENT

4. PUMP ADJUSTMENT TOOL MONITOR SCREEN

MC-02 TESTER

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


Service tools for pump adjustment Version1.0 RBAJ

1 ROM COVEC-F MITSUBISHI 12V


Inspection/adjustment

2 VRZ MITSUBISHI 12V


Inspection/adjustment

ROM COVEC-F MAZDA 12V


3 Inspection/adjustment

4 Manual operation

5 Workshop name registration

Exit
6

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

- 76 -
ADJUSTMENT

5. PUMP ADJUSTMENT TOOL MONITOR SCREEN OUTLINE


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

Pump information
1 N 0 r/min
44-6666
44-3032
000000000b 19
2 T 0.0 deg C 00000-000-0000b
VRZ 4M41
3 Rotation Right
20
Ua-ist V 4 cylinders
ECU MELCO
4 3 Mode Adjustment
Q 0.0 mm /st Pump type VRZ(12V) 21
5 Pt 0.000 MPa
6 Qo 0.0 l/h
7 TF
2001-01-15 11:28:44
22
V MENU Part number input
17
8 VTPS V
9 16
TPS V
10
Only items necessary for each TA mm
step are displayed. 11 DQ 0.0 mm3/st
23
Circled numbers indicate fields 24
where input is necessary. 12 Zero set

13 Soll-cor

Step information
Back Next No. STEP N Soll Soll-cor TCVF DTCV

18 Step status 03 P_cham_ADJ 1000rpm 2.91v 0.00mv 60Hz 100%


Comment PT standard point

14 Next
Sequence 03 / 32 After values are input, push 'Next' button. 25
15 Select 04 500rpm 2.50v 60Hz 0%
P-VRZR- 347

No. Name Use and purpose


1 Pump speed input N: pump speed Input the pump's speed.
2 Test oil temperature input T: test oil temperature Input the test oil temperature.
3 Actual control sleeve position voltage U soll: actual control sleeve position Displays actual control sleeve position voltage.
display voltage
4 Pump injection quantity input Q: pump injection quantity Input pump's injection quantity.
5 Pump chamber pressure input Pt: pump chamber pressure Input pump's chamber pressure.
6 Pump overflow quantity input Qo: pump overflow quantity Input pump's overflow quantity.
7 TF output display TF: fuel temperature Displays fuel temperature output voltage.
8 VTPS output display VTPS: voltage at 0 mm timer stroke Displays VTPS output voltage (voltage at 0 mm timer stroke).
9 TPS output display TPS: timer piston sensor output voltage Displays TPS (timer piston sensor) output voltage.
10 TA output display TA: timer stroke Displays TA (timer stroke) output.
11 Variation between cylinders display DQ: variation between cylinders Input pump's variation between injection quantities.
12 Zero setting key TPS output voltage at TA = 0 mm can be set at 0 V.
13 Target control sleeve position Any control sleeve position can be set by setting the compensation
compensation voltage key voltage.
14 NEXT key To set at next step.
15 Keys for moving to next or previous step To set at any step ( BACK, NEXT).
16 Menu key To set at MENU display.
17 Part number input key To set at part number input display.
18 Step status display Displays step status. Changes from red to green when all items
are within specifications.
19 Part number, serial number display Displays pump information part number (specification, pump) and
serial number (pump, GE).
20 Specification display Displays pump information specifications.
21 Measurement mode display Displays pump information measurement mode (inspection,
adjustment).
22 Measurement date display Displays date and time of measurements.
23 Status display Displays step status. Green: within specifications; red: outside 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)
Pump adjustment tools for service Second timing adjustment (manual operation)

MC-02 TESTER
Manual operation
ECU reader data

Item Value Unit Item Value Unit

1 GE Vist V TPS Vist V

Item Value Unit Item Value Unit

TF deg C Np 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 V 1. Values must be input for GE soll, TCV Duty and TCV Frequency.
2. Np values do not appear at VRZ pump adjustment.
GE Soll-cor mV
TCV Duty %
TCV Frequency Hz
3 Initialize ECU

4 Menu

P-VRZR- 348

No. Name Remarks


1 Control sleeve position actual voltage Displays actual control sleeve position voltage.
display
2 Control sleeve position target voltage By operating the input keys, the control sleeve position can be set
display 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)
Pump adjustment tools for service Workshop name registration

MC-02 TESTER
Workshop name registration

1 Workshop name RBAJ


2 Address JAPAN
3 Telephone 000-000-0000
4 Fax 111-111-1111

5 Operator's name sse


6 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
MC-02 TESTER

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


(1) Select Workshop name registration.
Service tools for pump adjustment Version1.0 RBAJ

ROM COVEC-F MITSUBISHI 12V


Inspection/adjustment

VRZ MITSUBISHI 12V


Inspection/adjustment

ROM COVEC-F MAZDA 12V


Inspection/adjustment

Manual operation

(1)
Workshop name registration

Exit

P-VRZR- 346

(2) Input the company name, etc, in the fields


MC-02 TESTER
Workshop name registration on the screen.
(3) Click the Registration button.
Workshop name RBAJ
Address JAPAN Note:
Telephone 000-000-0000 (2)
Fax 111-111-1111 The default password at setup is RBAJ.
Operator's name

Password
sse
****
Input a new password if desired. (The only limit
to the number of figures and letters in the
Input items and select Registration button.
password is the size of the input field.)
(3)

Menu Registration

P-VRZR- 350

- 79 -
ADJUSTMENT

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

See page 81 [1]

Preparation

See page 81 [2], 82 [3]

Part no. input and installation confirmation


See page 83 [4]

Warming-up operation

See page 84 [5]

Pre-stroke adjustment
See page 64 (9)

Pump chamber pressure adjustment

See page 85 [6]

Standard injection quantity point adjustment


See page 86 [7]

Pump chamber pressure confirmation


See page 86 [8]

TPS zero setting


See page 87 [9]

Timer stroke and characteristic confirmation

See page 88 [10]

Non-injection confirmation
See page 88 [11]

Injection quantity compensation point adjustment


See page 89 [12]

Compensation ROM interpolation calculation


See page 89 [13]

Writing to the compensation ROM

See page 90 [14]

Magnet valve operation confirmation


See page 90 [15]

Second timing adjustment


See page 94 (4)

Finish

- 80 -
ADJUSTMENT

[1] Recording the pump and GE serial


numbers
(1) Read and record the 10 digit pump serial
number.
Advice
It is easier to read the pumps serial number
Pump serial number
before beginning Preparation.
Note:
Serial number input is used during adjustment
mode and inspection mode.
Pump serial no. under EEPROM P-VRZR- 351

(2) Read and record the 13 digit GE actuators


serial number.
Advice
It is easier to read the GE actuators serial
number before beginning Preparation.
Note:
Serial number input is used during adjustment
mode and inspection mode.
GE serial number

GE serial number
P-VRZR- 352

[2] Preparation
(1) Connect the test oil hose to the injection
pump. (Refer to page 69 for the fuel piping.)
(2) Connect the injection system piping to the
Test oil hose
Injection system piping injection pump. (Refer to page 68 for the
injection system piping.)
(3) Connect the controller assemblys wire
harness and intermediate harness to the
injection pumps connectors. (Refer to page
70 for the controller assemblys wiring.)
(4) Connect the ROM controllers wire harness
P-VRZR- 353
and intermediate harness to the injection
pumps VRZ EEPROM connector.
(5) Connect the FCV GND harness to the
controller assemblys wire harness and to
ROM harness
earth.
(6) Connect the D-Sub 9 pin cable connector
COM2 COM1
(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
Controller unit the personal computer using the wire
Controller assembly harness for VRZ adjustment P-VRZR- 354 harness.

- 81 -
ADJUSTMENT

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

P-VRZR- 355

FCV (magnet valve) ON/OFF switch (11) Connect the wire harness to the controller
Sub-switch units No 2 ECU connector.
(12) Turn the main switch on the rear of the
controller unit ON.
(13) Set the No 1 ~ No 4 changeover switch at
No 2.
(14) Turn the FCV (magnet valve) ON/OFF
switch ON to energize the magnet valve.
(15) Turn the sub switch on the front of the
ECU for VRZ type controller unit ON.
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.
MC-02 TESTER (3) Input the password and press the Enter key.
Precaution
Advice
Password is required to actuate adjustment tools. Input the initial default password RBAJ or
Input password and press ENTER key. your own password.

(3)
P-VRZR- 357

- 82 -
ADJUSTMENT

[4] P a r t n u m b e r input and


MC-02 TESTER

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


Service tools for pump adjustment Version1.0 RBAJ
confirmation
ROM COVEC-F MITSUBISHI 12V
(1) Select the VRZ [Mitsubishi 12V] Inspection/
Inspection/adjustment

VRZ MITSUBISHI 12V


(1) adjustment button.
Inspection/adjustment

ROM COVEC-F MAZDA 12V


Inspection/adjustment

Manual operation

Workshop name registration

Exit

P-VRZR- 346

(2) When the dialog shown at left appears, input


MC-02 TESTER
Part number input the specified part number (6 digits) and
If number input is correct, select Next button.
If you need to input a different number, select Clear button.
press Enter.
(2)
(3) Input the pump part number (last 6 digits)
Specified part no. 446613 Pump serial no. 0880052496 (4)
(6 digits)
Pump part no. 443062
(10 digits)
GE serial no. 5062008852056 (5) and press Enter.
(3) (last 6 digits) (13 digits)

System specifications
Engine model VRZ_4M41
1. Specified part no.
Pump Pump
OEM
Specified part no.
(4) Input the pump serial number (10 digits) and
part no. type

press Enter.
Adjustment Inspection
Rotation Right 104700-304* 003040 008040
104700-305* COVEC-F 003051 008051
Pump cylinders 4 cylinders 104700-306* MITSUBISHI 003060 008060
ECU MELCO 109144-305*
109144-306*
VRZ

104700-055* COVEC-F MAZDA


44-6613 44-8813

000550 008550
(5) Input the GEs serial number (13 digits) and
2. Pump part no.

Mode Adjustment
Example:
Full pump no.
109144-3052
104700-0551
Input pump part no.
443052
000551
press Enter.
(6)
(6) Press the Next key.
Menu Clear Next

P-VRZR- 358

(7) Confirm that the screen changes to the


MC-02 TESTER
Setup confirmation injection system piping display.
Installation confirmation
Click on appropriate item
and explanatory illustration is displayed.
Key no.
1
Part name
Injection pipe
Part no.
157808-4720
Note
Note:
2 Nozzle & nozzle holder assembly 1 688 901 035
1. Injection system piping

2. Overflow piping
3
4
Joint
Injection tube
Same as VP44
Clicking the different buttons (1. Injection system
3. Adjustment controller wiring

4. Operation sequence 3
piping, 2. Overflow piping, 3. Adjustment
2 4 controller wiring, and 4. Operation sequence)
displays different Setup confirmation screens.

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

Back Next

P-VRZR- 359

- 83 -
ADJUSTMENT

Service tools for pump adjustment Adjustment display


[5] Warming-up operation
Status Item Measured / input value Unit Specification Tolerance Pump information

N 0 r/min
Specified part no.

Pump part no.


44-6613

44-3062
(1) Set the pump test bench delivery pressure
T 0.0 deg C
Pump serial no.

GE serial no.
0880052496
50620-088-52056 at the specified 40 kPa {0.4 kgf/cm2}.
(4)
(2) Confirm that the sequence is 01/31.
Engine model VRZ_4M41
Ua-ist V Rotation Right
Pump cylinders 4 cylinders

Q 0.0 mm3/st ECU

Mode
MELCO

Adjustment
(3) Run the injection pump at the specified
Pump type VRZ (12V)
speed N (see figure at left).
05/04/03 13:20:52 (4) Measure N, T and Q on the pump test bench
Part number input

and input the values.


Menu

Step information
No. Step name N Soll Soll-cor Frequency Duty
(5) Step status Present step 01 Warm-up 300r/min 2.80v 0.00mv 60Hz 100%

Next
Comment Check for fuel leaks.
Note:
(6)
U ist is displayed automatically.
Sequence 01 / 31 After values are input, push Next button.
Select 02 Warm-up 1000r/min 2.91v 0.00mv 60Hz 100%

(2)
(5) Confirm that the Step status field is green.
P-VRZR- 360
(6) Proceed to the next step.
Advice
If U ist values are not as specified, press
the Next button several times. Then, return
to Step 01/31 using the back arrow.
Repeat the Step 01/31 and confirm that U
ist values are as specified.
Note:
If not as specified after confirming U ist several
times, the GE may be faulty.

Service tools for pump adjustment Adjustment display


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

N
Measured / input value

0 r/min
Unit Specification Tolerance Pump information
Specified part no.

Pump part no.


44-6613

44-3062
(8) Run the injection pump at the specified
T 0.0 deg C
Pump serial no.

GE serial no.
0880052496
50620-088-52056
speed N (see figure at left).
(9)
Ua-ist V
Engine model

Rotation
VRZ_4M41
Right (9) Measure N, T and Q on the pump test bench
Pump cylinders 4 cylinders

Q 0.0 mm3/st ECU

Mode
MELCO

Adjustment
and input the values.
Pump type VRZ (12V)
Note:
05/04/03 13:21:45
U ist is displayed automatically.
Step information
No. Step name N Soll
Menu

Soll-cor
Part number input

Frequency Duty
(10) Confirm injection.
(13) Step status Present step
Comment
02
Warm-up
Warm-up 1000r/min 2.91v 0.00mv 60Hz 100%
(11) Confirm that no fuel leaks from the
Next
(14) Sequence 02 / 31 After values are input, push Next button.
injection pump fuel piping connections.
Select 03 P-cham_ADJ 1000r/min 2.91v 0.00mv 60Hz 100%

(7) P-VRZR- 361 CAUTION


If there are any fuel leaks, if there is no
injection or if any unusual noises occur
during operation, stop test bench operation
immediately and inspect the pump.
(12) Confirm that the injection pump is
operating normally.
(13) Confirm that the Step status field is green.
(14) Proceed to the next step.
Advice
Because the test oil temperature takes
longer to increase in cold weather, turn the
pump test bench on earlier.

- 84 -
ADJUSTMENT

Service tools for pump adjustment Adjustment display


Status Item Measured / input value Unit Specification Tolerance
[6] P u m p c h a m b e r pressure
Pump information

N 0 r/min
Specified part no.

Pump part no.

Pump serial no.


44-6613

44-3062 adjustment
0880052496
T 0.0 deg C GE serial no.

Engine model
50620-088-52056

VRZ_4M41
(1) Confirm that the sequence is 03/31.
(3) Ua-ist V Rotation

Pump cylinders
Right
4 cylinders
(2) Run the injection pump at the specified
Pt 0.000 MPa ECU

Mode
MELCO

Adjustment speed N (see figure at left).


Qo 0.0 I/h Pump type

(3) Measure N, T, Pt and Qo on the pump test


VRZ (12V)

TF V
Menu
05/04/03 13:22:24
Part number input
bench and input the values.
Step information
No. Step name N Soll Soll-cor Frequency Duty Note:
(7) Present step

U ist and Tf are displayed automatically.


Step status 03 P-cham_ADJ 1000r/min 2.91v 0.00mv 60Hz 100%
Comment PT standard point
Next
(8) Sequence 03 / 31 After values are input, push Next button.
Select 04 Rough-Q_ADJ 1000r/min 2.91v 0.00mv 60Hz 100% (4) If Pt is as specified, perform steps (7) and
(1) P-VRZR- 362
(8). If Pt is not as specified, adjust as
described below.
When the pump chamber pressure exceeds
Holder the specifications
Plug
Replace the regulating valve assembly and
adjust the pump chamber pressure to the
Spring specified pressure.
When the pump chamber pressure is less than
Piston the specifications

Stopper
Adjusting device Attach the adjusting device to the regulating
valve.
P-VRZR- 240 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 Remarks

Adjusting device 157829-0820

(5) Measure N, T, Pt and Qo again on the pump


test bench and input the values.
(6) Confirm that the injection pump is operating
normally.
(7) Confirm that the Step status field is green.
(8) Proceed to the next step.
Advice
If the overflow quantity is not as specified
after confirming pump chamber pressure,
check the overflow valve.

- 85 -
ADJUSTMENT

Service tools for pump adjustment Adjustment display


Status Item Measured / input value Unit Specification Tolerance Pump information
[7] Standard injection quantity point
N 0 r/min
Specified part no.

Pump part no.

Pump serial no.


44-6613

44-3062
0880052496
adjustment
T 0.0 deg C GE serial no.

Engine model
50620-088-52056

VRZ_4M41
(1) Confirm that the sequence is 04/31.
(3) Ua-ist V Rotation

Pump cylinders
Right
4 cylinders (2) Run the injection pump at the specified
Q 0.0 mm3/st ECU MELCO

Mode Adjustment speed N (see figure at left).


DQ 0.0 mm /st 3 Pump type VRZ (12V)

(3) Measure N, T, Q and DQ on the pump test


Menu
05/04/03 13:23:05
Part number input
bench and input the values.
(9)
Step information
Step status Present step
No.
04
Step name
Rough-Q_ADJ
N
1000r/min
Soll
2.91v
Soll-cor
0.00mv
Frequency
60Hz
Duty
100%
Note:
Next
Comment Standard Q adjustment (GE adjustment)
U ist is displayed automatically.
(10) Sequence 04 / 31 After values are input, push Next button.
Select 05 P-cham_ADJ 1000r/min 2.91v 0.00mv 60Hz 100%
(4) If Q is as specified, perform steps (9) and
(1) P-VRZR- 363
(10). If Q is not as specified, adjust as
described below.
Injection quantity decrease (5) To adjust the fuel injection quantity, loosen
(move GE actuator toward drive side)
the torx bolts so that the GE actuator can
Move GE actuator to adjust
move a little.
(6) Move the GE actuator in the drive shafts
axial direction to adjust the full load injection
Injection quantity increase
quantity. (To increase the injection quantity,
(move GE actuator toward move the GE actuator toward the distributor
distributor head side) head. To decrease the injection quantity,
move the GE actuator toward the drive side.)
Record the measured injection quantity and
GE actuator the position of the GE actuator to facilitate
P-VRZR- 355
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.

Service tools for pump adjustment Adjustment display


[8] P u m p c h a m b e r pressure
Status Item

N
Measured / input value

0 r/min
Unit Specification Tolerance Pump information
Specified part no.

Pump part no.


44-6613

44-3062
confirmation
T 0.0 deg C
Pump serial no.

GE serial no.
0880052496
50620-088-52056 (1) Confirm that the sequence is 05/31.
VRZ_4M41

(2) Run the injection pump at the specified


Engine model

(3) Ua-ist V Rotation Right


Pump cylinders 4 cylinders

Pt 0.000 MPa ECU

Mode
MELCO

Adjustment
speed N (see figure at left).
Qo 0.0 I/h Pump type VRZ (12V)
(3) Measure N, T, Pt and Qo on the pump test
TF V
05/04/03 13:23:42 bench and input the values.
Part number input

Note:
Menu

Step information
No. Step name N Soll Soll-cor Frequency Duty

U ist and TF are displayed automatically.


Present step
(5) Step status
Comment
05 P-cham_ADJ
Reconfirmation of PT standard point
1000r/min 2.91v 0.00mv 60Hz 100%

Next
(6) Sequence

(4) Confirm the pump chamber pressure.


05 / 31 After values are input, push Next button
Select 06 Zero_set 500r/min 2.50v 0.00mv 60Hz 100%

(1) P-VRZR- 364


(5) Confirm that the Step status field is green.
(6) Proceed to the next step.
Advice
Recheck the feed pump.

- 86 -
ADJUSTMENT

Service tools for pump adjustment Adjustment display


Status Item Measured / input value Unit Specification Tolerance Pump information
[9] TPS zero setting
(3)
N 0 r/min
Specified part no.

Pump part no.


44-6613

44-3062 (1) Confirm that the sequence is 06/31.


Pump serial no. 0880052496
T 0.0 deg C GE serial no.

Engine model
50620-088-52056

VRZ_4M41
(2) Run the injection pump at the specified
Ua-ist V Rotation

Pump cylinders
Right
4 cylinders
speed N (see figure at left).
VTPS V ECU

Mode
MELCO

Adjustment (3) Measure N and T on the pump test bench


TPS V Pump type VRZ (12V)
and input the values.
(4) 05/04/03 13:24:16 Note:
U ist, VTPS and TPS are displayed
Zero set Menu Part number input

Step information
No. Step name N Soll Soll-cor Frequency Duty
Present step
(7) Step status 06 Zero_set 500r/min 2.50v 0.00mv 60Hz 100%

Next
Comment Confirm initial TPS output.
automatically.
(8) Sequence 06 / 31 After values are input, push Next button.
Select 07 Timer_TA 100r/min 2.41v 0.00mv 60Hz 100% (4) Press the Zero set key and confirm that the
(1) VTPS value is within the specifications.
P-VRZR- 365
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
Th/ness Th/ness
Shim part no Shim part no
(mm) (mm)

Spring
149653-0200 0.2 149653-0500 2.1
(9 443 613 473) (9 443 613 475)
TPS output adjustment 149653-0300 0.6 149653-0600 2.5
(TPS standard point shim) P-VRZR- 137 (9 443 612 841) (9 443 612 842)
149653-0400 1.0 149653-0700 2.9
(9 443 613 474) (9 443 613 476)

(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

Service tools for pump adjustment Adjustment display


Status Item Measured / input value Unit Specification Tolerance
[10] Timer stroke and characteristic
Pump information

N 0 r/min
Specified part no.

Pump part no.

Pump serial no.


44-6613

44-3062 confirmation
0880052496

(3)
T 0.0 deg C GE serial no.

Engine model
50620-088-52056

VRZ_4M41
(1) Confirm that the sequence is 07/31.
Ua-ist V Rotation

Pump cylinders
Right
4 cylinders
(2) Run the injection pump at the specified
Pt 0.000 MPa ECU

Mode
MELCO

Adjustment speed N (see figure at left).


VTPS V Pump type

(3) Measure N, T and Pt on the pump test bench


VRZ (12V)

TA mm
Menu
05/04/03 13:20:52
Part number input
and input the values.
Step information
Present step
No. Step name N Soll Soll-cor Frequency Duty Note:
U i s t , V T P S a n d TA a r e d i s p l a y e d
Step status Timer_TA 100%
(5) Comment
07
100r/min
100r/min 2.41v 0.00mv 60Hz

Next
(6) Sequence 07 / 31 After values are input, push Next button.
Select 08 Timer_TA 50r/min 2.41v 0.00mv 60Hz 100% automatically.
(1) P-VRZR- 366 (4) Confirm that the timer stroke is within the
specifications.
TPS
(5) Confirm that the Step status field is green.
(6) Proceed to the next step.
Note:
Because the TPS standard point shim was
Timer stroke adjusting shim adjusted in Step 06/31, it cannot be changed.

Spring

Pump housing P-VRZR- 137

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


Service tools for pump adjustment Adjustment display
Status Item Measured / input value Unit Specification Tolerance Pump information
Specified part no. 44-6613 revolutions (Step 16/31) using the same
N 0 r/min Pump part no. 44-3062

T 0.0 deg C
Pump serial no.

GE serial no.
0880052496
50620-088-52056
procedure used for 100 revolutions (Step 7/31)
Ua-ist V
Engine model

Rotation
VRZ_4M41
Right
above.
Pt 0.000 MPa
Pump cylinders

ECU
4 cylinders
MELCO Advice
Repeat Step 06/31 if the timer stroke is not
Mode Adjustment

VTPS V Pump type VRZ (12V)

TA mm as specified.
05/04/03 13:25:27
Menu Part number input

Step information
No. Step name N Soll Soll-cor Frequency Duty
Step status Present step 08 Timer_TA 50r/min 2.41v 0.00mv 60Hz 100%
Comment 50r/min
Next
Sequence 08 / 31 After values are input, push Next button.
Select 09 Timer_TA 325r/min 1.53v 0.00mv 60Hz 100%

P-VRZR- 367

Service tools for pump adjustment Adjustment display


[11] Non-injection confirmation
Status Item Measured / input value Unit Specification Tolerance Pump information

N 0 r/min
Specified part no.

Pump part no.


44-6613

44-3062
(1) Confirm that the sequence is 17/31.
T 0.0 deg C
Pump serial no.

GE serial no.
0880052496
50620-088-52056 (2) Run the injection pump at the specified
speed N (see figure at left).
Engine model VRZ_4M41
(3) Ua-ist V Rotation Right
Pump cylinders 4 cylinders

Q 0.0 mm3/st ECU

Mode
MELCO

Adjustment
(3) Measure N, T, Q and DQ on the pump test
DQ 0.0 mm3/st Pump type VRZ (12V)
bench and input the values.
05/04/03 13:35:08
Note:
U ist is displayed automatically.
Menu Part number input

Step information
No. Step name N Soll Soll-cor Frequency Duty
Present step
(4) Step status 17 Q_characteristics 2300r/min 0.87v 0.00mv 60Hz 100%

Next
Comment Confirm no nozzle injection. (4) Confirm that the Step status field is green.
(5)
(5) Proceed to the next step.
Sequence 17 / 31 After values are input, push Next button.
Select 18 Cor-Q_ADJ 1900r/min 3.73v 0.00mv 60Hz 100%

(1)
P-VRZR- 368

- 88 -
ADJUSTMENT

Service tools for pump adjustment Adjustment display


[12] Injection quantity compensation
Status Item Measured / input value Unit Specification Tolerance Pump information

N 0 r/min
Specified part no.

Pump part no.

Pump serial no.


44-6613

44-3062
point adjustment
0880052496
T 0.0 deg C GE serial no.

Engine model
50620-088-52056

VRZ_4M41
(1) Confirm that the sequence is 18/31.
(3) Ua-ist V Rotation Right
(2) Run the injection pump at the specified
Pump cylinders 4 cylinders

Q 0.0 mm3/st ECU

Mode
MELCO

Adjustment speed N (see figure at left).


DQ 0.0 mm3/st Pump type

(3) Measure N, T, Q and DQ on the pump test


VRZ (12V)

(4) Soll-cor Menu


05/04/03 13:36:03
Part number input
bench and input the values.
Step information
No. Step name N Soll Soll-cor Frequency Duty Note:
(6) Present step

U ist is displayed automatically.


Step status 18 Cor-Q_ADJ 1900r/min 3.73v 0.00mv 60Hz 100%
Comment Correction point 10
Next
(7) Sequence 18 / 31 After values are input, push Next button.
Select 19 Cor-Q_ADJ 1900r/min 1.53v 0.00mv 60Hz 100% (4) If the injection quantity is not as specified,
(1) P-VRZR- 369
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
Service tools for pump adjustment Adjustment display
Status Item Measured / input value Unit Specification Tolerance Pump information
Specified part no. 44-6613
N 0 r/min Pump part no.

Pump serial no.


44-3062
0880052496 specification
T 0.0 deg C GE serial no. 50620-088-52056

Ua-ist V
Engine model

Rotation
VRZ_4M41
Right
Input the value only to the compensation voltage
Pump cylinders 4 cylinders

Q 0.0 mm3/st ECU

Mode
MELCO

Adjustment
(6) Confirm that the Step status field is green.
DQ 0.0 mm3/st Pump type VRZ (12V)
(7) Proceed to the next step.
05/04/03 13:36:43
Soll- cor Part number input

Confirm compensation point 9 (Step 19/31) ~


Menu

Step information
No. Step name N Soll Soll-cor Frequency Duty
Step status Present step 19 Cor-Q_ADJ 1900r/min 1.53v 0.00mv 60Hz 100%

Next
Comment Correction point 9 compensation point 1 (Step 27/31) using the
same procedure used for compensation point
Sequence 19 / 31 After values are input, push Next button.
Select 20 Cor-Q_ADJ 1000r/min 2.91v 0.00mv 60Hz 100%

10 (Step 18/31) above.


P-VRZR- 370
After adjusting the compensation point 1,
press the Next button to automatically
Service tools for pump adjustment Adjustment display
Status Item Measured / input value Unit Specification Tolerance Pump information
Specified part no. 44-6613
proceed to Step 28/31.
Pump part no. 44-3062
Pump serial no. 0880052496
GE serial no. 50620-088-52056

Engine model

Rotation
VRZ_4M41
Right
[13] Compensation ROM interpolation
Injection quantity input data is outside
specification after correction point 1.
Pump cylinders

ECU

Mode
4 cylinders
MELCO

Adjustment
calculation
Pump type VRZ (12V)
Note:
05/04/03 13:43:00
In Step 28/31 the adjustment software
Step information
No. Step name N Soll
Menu

Soll-cor
Part number input

Frequency Duty
automatically performs the calculations.
Step status Present step
Comment
28 Q-ROM_CAL
Q-ROM intermediate point calculation
0r/min 0.00v 0.00mv 60Hz 0%
If the compensation voltage Soll values are
Next
Sequence

Select
28 / 31

29
After values are input, push Next button.
ROM_overwrite 0r/min 0.00v 0.00mv 60Hz 0%
not correct, compensation calculations are
not performed and an error is displayed. If
P-VRZR- 371 an error is displayed, repeat Step 18/31.

- 89 -
ADJUSTMENT

Service tools for pump adjustment Adjustment display


[14] Writing to the compensation ROM
Status Item Measured / input value Unit Specification Tolerance Pump information
Specified part no.

Pump part no.


44-6613

44-3062
(1) Press Step 28/31 to automatically display
Pump serial no.

GE serial no.
0880052496
50620-088-52056
the step.
Engine model

Rotation
VRZ_4M41
Right (2) The adjustment software automatically
Injection quantity input data is outside Pump cylinders 4 cylinders

specification after correction point 1.


ECU

Mode
MELCO

Adjustment
writes the compensation Q data to the
Pump type VRZ (12V)
injection pumps Q adjustment ROM.
05/04/03 13:43:34
Advice
Step information
No. Step name N Soll
Menu

Soll-cor
Part number input

Frequency Duty
Never touch the computer, the injection
pump or the connecting wire harnesses
Step status Present step 29 ROM_overwrite 0r/min 0.00v 0.00mv 60Hz 0%
Comment Overwrite Q-ROM.
Next
Sequence

Select
29 / 31

30 Stop_Q
After values are input, push Next button.
1000r/min 2.91v 0.00mv 60Hz 0%
while writing to the ROM.
(1) P-VRZR- 372

Service tools for pump adjustment Adjustment display


Status Item Measured / input value Unit Specification Tolerance Pump information
[15] M a g n e t v a l v e o p e r a t i o n
N 0 r/min
Specified part no.

Pump part no.

Pump serial no.


44-6613

44-3062
0880052496
confirmation
(3)
T 0.0 deg C GE serial no.

Engine model
50620-088-52056

VRZ_4M41
(1) Confirm that the sequence is 30/31.
Ua-ist V Rotation

Pump cylinders
Right
4 cylinders (2) Run the injection pump at the specified
Q 0.0 mm3/st ECU MELCO

Mode

Pump type
Adjustment

VRZ (12V)
speed N (see figure at left).
(3) Measure N, T and Q on the pump test bench
Menu
05/04/03 13:44:15
Part number input
and input the values.
Step information
Step status Present step
No.
30 Stop_Q
Step name N
1000r/min
Soll
2.91v
Soll-cor
0.00mv
Frequency
60Hz
Duty
100%
Note:
U ist is displayed automatically.
Comment Confirm no nozzle injection when the FCV is OFF.
Next
Sequence 30 / 31 After values are input, push Next button.
Select 31 Q_characteristics 0r/min 2.91v 0.00mv 60Hz 100%

(1)
P-VRZR- 373

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

P-VRZR- 356

Service tools for pump adjustment Adjustment display


(5) Measure N, T and Q again on the pump
Status Item

N
Measured / input value

0 r/min
Unit Specification Tolerance Pump information
Specified part no.

Pump part no.


44-6613

44-3062
test bench and input the values.
T 0.0 deg C
Pump serial no.

GE serial no.
0880052496
50620-088-52056
(6) Confirm that the Step status field is green.
(5)
Ua-ist V
Engine model

Rotation
VRZ_4M41
Right
(7) Proceed to the next step.
Pump cylinders 4 cylinders

Q 0.0 mm3/st ECU MELCO

Mode Adjustment
Pump type VRZ (12V)

05/04/03 13:44:15
Menu Part number input

Step information
No. Step name N Soll Soll-cor Frequency Duty
(6) Step status Present step
Comment
30 Stop_Q 1000r/min 2.91v 0.00mv 60Hz 100%
Confirm no nozzle injection when the FCV is OFF.
Next
(7) Sequence 30 / 31 After values are input, push Next button.
Select 31 Q_characteristics 0r/min 2.91v 0.00mv 60Hz 100%

P-VRZR- 373

- 90 -
ADJUSTMENT

[16] Second timing adjustment


Note:
The following describes the preparation for and
Sub-switch performance of automatic adjustment of second
timing.
(1) Injection pump disassembly
(1) Turn the sub-switch OFF.

P-VRZR- 356

Fuel piping Injection pump Coupling (2) Disconnect the intermediate harness
connectors.
(3) Disconnect the fuel piping.
(4) Remove the coupling.
(5) Remove the pump from the fixing stand.
(6) Remove the fixing stand.

Fixing stand
Harness connectors P-VRZR- 375

O-ring (2) Drive gear installation


(1) Temporarily assemble the O-ring and
bracket to the pump housing.
Nuts (3)

Bracket P-VRZR- 252

(2) Assemble the drive shaft key in the drive


shafts key groove.

Key

P-VRZR- 253

- 91 -
ADJUSTMENT

(3) Assemble the drive gear to the drive shaft.

Drive gear

P-VRZR- 254

(4) Assemble the drive gear fixing round nut to


the drive shaft and tighten it lightly.

Round nut

P-VRZR- 255

(5) Assemble the wrench to the drive gear and


tighten the round nut (SW21) to the specified
Wrench torque using a torque wrench.
Specified torque: 167 ~ 185 Nm
{17 ~ 18.7 kgfm}
Tool name Part no Remarks
Wrench 157917-4620

Torque wrench P-VRZR- 256

- 92 -
ADJUSTMENT

(3) Injection pump installation


(1) Attach the stand to the pump test bench.
Stand Tool name Part no Remarks
Stand 105781-0890

P-VRZR- 258

(2) Attach the injection pump to the stand.


Stand
(3) Pull the stands handle as shown in the figure
to fix the injection pump.

P-VRZR- 259

Pipe assembly (4) Remove the CPV from cylinder B and attach
the pipe assembly and the gasket.
Tool name Part no Remarks
Pipe assembly 157845-9520

P-VRZR- 260

Plugs (5) Connect the test oil hose to the injection


pump.
(6) Attach the plugs to where the GE and the
distributor head overflow valves were
removed.
Advice
Install any suitable plugs to maintain pump
chamber air tightness.

Test oil hose P-VRZR- 261

- 93 -
ADJUSTMENT

(7) Connect the controller assemblys main


Main harness
harness and intermediate harness to the
injection pumps GE connector.
Tool name Part no Remarks
Main harness 157966-4920
Intermediate
157966-5720
harness

Intermediate harness P-VRZR- 262

Adjusting device Chamfered tooth (8) Align the adjusting devices pin hole with the
injection pump brackets pin. In this position,
attach the adjusting device to the injection
pumps bracket and fix using the bolts.
Tool name Part no Remarks
Pin Rack
Adjusting
Rack teeth 105793-0020
Pin hole device

Advice
When aligning the adjusting devices pin hole
with the brackets pin, position the adjusting
P-VRZR- 263 devices rack teeth on either side of the drive
gears chamfered tooth.
(4) Second timing adjustment
(1) Turn the controller units sub-switch ON.
(2) Supply test oil to the injection pump at the
Sub-switch specified pressure of 20 kPa {0.2 kgf/cm2}.

P-VRZR- 356

Service tools for pump adjustment Adjustment display


(3) Confirm that the sequence is Step 31/31 (Q
characteristics).
Status Item Measured / input value Unit Specification Tolerance Pump information
Specified part no. 44-6613
N 0 r/min Pump part no. 44-3062
Pump serial no. 0880052496
T 0.0 deg C GE serial no. 50620-088-52056

Engine model VRZ_4M41


Ua-ist V Rotation Right
Pump cylinders 4 cylinders

Q 0.0 mm /st 3 ECU MELCO

Mode Adjustment

DQ 0.0 mm3/st Pump type VRZ (12V)

05/04/03 13:44:46
Menu Part number input

Step information
No. Step name N Soll Soll-cor Frequency Duty
Step status Present step 31 Q_characteristics 0r/min 2.91v 0.00mv 60Hz 100%
Comment Second timing
Next
Sequence 31 / 31 After values are input, push Next button.
Select _
Adjustment finished

(3) P-VRZR- 376

- 94 -
ADJUSTMENT

Nuts (3) (4) Loosen the injection pump bracket


installation nuts.

P-VRZR- 264

FBB plate (5) Loosen the bolt preventing drive shaft


Bolt preventing drive rotation and remove the FBB plate.
shaft rotation

P-VRZR- 265

Pipe assembly Adjusting device (6) Insert the lever into the adjusting device and
turn the lever once in the reverse rotation
direction, then turn the lever in the direction
of rotation.
(7) Adjust so that test oil flows from cylinder Bs
pipe assembly at a rate of 1 drop / 3
seconds.

P-VRZR- 266

(8) Tighten the bolt preventing drive shaft


Bolt preventing drive rotation to fix the drive shaft.
shaft rotation Specified torque: 27 ~ 35 Nm
{2.8 ~ 3.6 kgfm}

P-VRZR- 267

- 95 -
ADJUSTMENT

Nuts (3) (9) Tighten the bracket nuts.


Specified torque: 34 ~ 39 Nm
{3.5 ~ 4.0 kgfm}

P-VRZR- 268

(10) Mark the timing mark on the injection pump


Timing mark and the bracket.
Advice
Erase the previous mark.

P-VRZR- 269

FBB plate (11) Loosen the bolt preventing drive shaft


Bolt preventing drive
shaft rotation rotation, install the FBB plate and fix the
FBB plate by tightening the bolt preventing
drive shaft rotation.
Specified torque: 10 ~ 15 Nm
{1.0 ~ 1.5 kgfm}
(12) Turn the test oil switch OFF.

P-VRZR- 270

Service tools for pump adjustment Adjustment display


Status Item Measured / input value Unit Specification Tolerance Pump information
(13) Measure T on the pump test bench and
N 0 r/min
Specified part no.

Pump part no.

Pump serial no.


44-6613

44-3062 input the value.


0880052496
(13) T 0.0 deg C GE serial no. 50620-088-52056
Note:
U ist is displayed automatically.
Engine model VRZ_4M41
Ua-ist V Rotation Right
Pump cylinders 4 cylinders

Q 0.0 mm3/st
(14) Confirm that the Step status field is green.
ECU MELCO

Mode Adjustment

DQ 0.0 mm3/st Pump type VRZ (12V)

(15) Proceed to the next step.


05/04/03 13:44:46
Menu Part number input

Step information
No. Step name N Soll Soll-cor Frequency Duty
Present step
(14) Step status
Comment
31 Q_characteristics
Second timing
0r/min 2.91v 0.00mv 60Hz 100%

Next
(15) Sequence 31 / 31
_
After values are input, push Next button.
Select Adjustment finished

P-VRZR- 376

- 96 -
ADJUSTMENT

(5) Printing the adjustment results and


MC-02 TESTER
Adjustment result saving the test record
Specified part no. 44-6613 Pump serial no. 0880052496
(1) Click the Next key.
Test complete Adjustment necessary
Pump part no. 44-3062 GE serial no. 50620-088-52056
ECU values Measured values
No. Result Step name N Uasoll Soll-cor TCVF DTCV N T Uaist Q DQ Pt Qo VTPS TA TPS TF

(2) Do you want to print and save test record


r/min V mv Hz % r/min DegC V mm /st mm /st MPa I/h V mm V V
1 Warm-up 300 2.80 0.00 60 100 0 0.0 0.00 0.0
2 Warm-up 1000 2.91 0.00 60 100 0 0.0 0.00 0.0
3 P-cham_ADJ 1000 2.91 0.00 60 100 0 0.0 0.00 0.000 0.0 0.00
4 Rough-Q_ADJ 1000 2.91 0.00 60 100 0 0.0 0.00 0.0 0.0

is displayed.
5 P-cham_ADJ 1000 2.91 0.00 60 100 0 0.0 0.00 0.000 0.0 0.00
6 Zero_set 500 2.50 0.00 60 0 0 0.0 0.00 0.00 0.00
7 Timer_TA 100 2.41 0.00 60 100 0 0.0 0.00 0.000 0.00 0.00
8 Timer_TA 50 2.41 0.00 60 100 0 0.0 0.00 0.000 0.00 0.00
9 Timer_TA 325 1.53 0.00 60 0 0 0.0 0.00 0.000 0.00 0.00
10
11
12
13
14
Timer_TA
Timer_TA
Timer_TA
Timer_TA
Timer_TA
375
375
500
1000
1000
1.53
1.53
1.53
2.91
2.91
0.00
0.00
0.00
0.00
0.00
60
60
60
60
60
0
100
100
100
100
0
0
0
0
0.0
0.0
0.0
Do you want0 to print0.0
and save
0.0
0.00
0.00
0.00
0.00
test record?
0.00 0.0
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
(3) Click OK.
15
16
17
18
Timer_TA
Timer_TA
Q_characteristics
Cor-Q_ADJ
1900
1900
2300
1900
3.73
3.73
0.87
2.91
0.00
0.00
0.00
0.00
60
60
60
60
100 OK 0
100
100
100
0
0
0
0.0Cancel 0.00
0.0
0.0
0.0
0.00
0.00
0.00
0.0
0.0
0.0
0.0
0.0
0.0
0.000
0.000
0.00
0.00
0.00
0.00
Note:
19 Cor-Q_ADJ 1900 3.73 0.00 60 100 0 0.0 0.00 0.0 0.0
20
21
22
23
Cor-Q_ADJ
Cor-Q_ADJ
Cor-Q_ADJ
Cor-Q_ADJ
1000
1000
600
600
1.53
2.91
1.53
2.20
0.00
0.00
0.00
0.00
60
60
60
60
100
100
100
100
0
0
0
0
0.0
0.0
0.0
0.0
0.00
0.00
0.00
0.00
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
If you select Cancel, you cannot continue to
24 Cor-Q_ADJ 600 1.86 0.00 60 100 0 0.0 0.00 0.0 0.0
25
26
27
28
Cor-Q_ADJ
Cor-Q_ADJ
Cor-Q_ADJ
Cor-Q_ADJ
600
375
325
100
1.53
1.86
1.86
2.41
0.00
0.00
0.00
0.00
60
60
60
60
100
100
100
100
0
0
0
0
0.0
0.0
0.0
0.0
0.00
0.00
0.00
0.00
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
the next step.
If no further measurements are required, select Next button.
To repeat a measurement, select Repeat button and input step number.
Next
Advice
Step number Repeat

The printed test record can be given to


(1) P-VRZR- 377
the customer.
The saved test record is a record of all
the data and must be handled carefully.
(4) Turn the controller units sub-switch OFF.
(5) Turn the controller units main switch OFF.

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

P-VRZR- 271

CPV (2) Replace cylinder Bs pipe assembly with the


CPV. At this time, replace the gasket with a
new one.

Pipe assembly P-VRZR- 272

- 97 -
ADJUSTMENT

Main harness (3) Disconnect the main harness and the


Plug intermediate harness from the injection
pump.
(4) Remove the test oil hose and the overflow
valve plugs from the injection pump.

Intermediate harness Test oil hose P-VRZR- 273

Torx bolts (4) (5) Install the Q adjustment ROM to the pump
housing.
Note:
Removing the inlet adapter facilitates
installation.
(6) Tighten the Q adjustment ROMs torx bolts.
Specified torque: 2 ~ 3 Nm
Q adjustment
{0.2 ~ 0.3 kgfm}
ROM Pump housing Tool name Part no Remarks
Bit
Holder 157915-9820
Holder P-VRZR- 393 Bit 157915-9301 T20

(7) Connect the overflow valves bypass hose


Overflow valve
to the injection pump.
Bypass hose (8) Tighten the overflow valves using a torque
wrench.
Specified torque: 20 ~ 29 Nm
{2 ~ 3 kgfm}

Overflow
valve
P-VRZR- 274

Stand
(9) Remove the injection pump from the test
bench.
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 units sub-switch ON.
(2) Supply test oil to the injection pump at the
Sub-switch specified pressure of 20 kPa {0.2 kgf/cm2}.

P-VRZR- 397

(3) Select Manual operation on the menu


MC-02 TESTER

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


display.
Service tools for pump adjustment Version1.0 RBAJ

ROM COVEC-F MITSUBISHI 12V


Inspection/adjustment

VRZ MITSUBISHI 12V


Inspection/adjustment

ROM COVEC-F MAZDA 12V


Inspection/adjustment

(3) Manual operation

Workshop name registration

Exit

P-VRZR- 346

- 99 -
ADJUSTMENT

MC-02 TESTER
(4) Select the ECU (a black point appears when
ECU reader data
Manual operation the ECU is selected).
Item Value Unit Item Value Unit (5) Press Initialize ECU after selecting the
GE Vist V TPS Vist V
ECU.
Item Value Unit Item Value Unit

TF deg C Np r/min
(6) Press the GE soll button and input 2.91
(4) Select ECU
into the field. Press the keyboards Enter
ROM COVEC-F MITSUBISHI 12V VRZ MITSUBISHI 12V ROM COVEC-F MAZDA 12V

ECU configuration data


Input
key.
(6) GE Soll V
(7) Press the TCV Duty button and input 100
1. Values must be input for GE soll, TCV Duty and TCV Frequency.
2. Np values do not appear at VRZ pump adjustment.
(7) GE Soll-cor
TCV Duty
mV
%
(8)
(5)
TCV Frequency
Initialize ECU
Hz
into the field. Press the keyboards Enter
Menu key.
P-VRZR- 348
(8) Press the TCV Frequency button and input
60 into the field. Press the keyboards
Nuts (3)
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 (10) Loosen the bolt preventing drive shaft


Bolt preventing drive rotation and remove the FBB plate.
shaft rotation

P-VRZR- 265

Pipe assembly Adjusting device (11) Insert the lever into the adjusting device
and turn the lever once in the reverse
rotation direction, then turn the lever in the
direction of rotation.
(12) Adjust so that test oil flows from cylinder
Bs pipe assembly at a rate of 1 drop /3
seconds.

P-VRZR- 266

- 100 -
ADJUSTMENT

(13) Tighten the bolt preventing drive shaft


Bolt preventing drive rotation to fix the drive shaft.
shaft rotation Specified torque: 27 ~ 35 Nm
{2.8 ~ 3.6 kgfm}

P-VRZR- 267

Nuts (3) (14) Tighten the bracket nuts.


Specified torque: 34 ~ 39 Nm
{3.5 ~ 4.0 kgfm}

P-VRZR- 268

(15) Mark the timing mark on the injection pump


Timing mark and the bracket.
Advice
Erase the previous mark.

P-VRZR- 269

FBB plate (16) Loosen the bolt preventing drive shaft


Bolt preventing drive
shaft rotation rotation, install the FBB plate and fix the
FBB plate by tightening the bolt preventing
drive shaft rotation.
Specified torque: 10 ~ 15 Nm
{1.0 ~ 1.5 kgfm}
(17) Turn the test oil switch OFF.
(18) Remove the injection pump as described
in (6) Injection pump removal [steps (1) to
(10)] on pages 97 to 99.
P-VRZR- 270

- 101 -
INSPECTION

INSPECTION
Inspection sequence
Recording the pump and GE serial numbers

See page 103 [1]

Preparation

See page 103 [2], 104 [3]

Part no. input and installation confirmation


See page 105 [4]

Warming-up operation

See page 106 [5]

Pump chamber pressure confirmation

See page 107 [6]

TPS confirmation
See page 107 [7]

Timer stroke confirmation

See page 107 [8]

Non-injection confirmation
See page 108 [9]

Injection quantity confirmation


See page 108 [10]

Magnet valve operation confirmation See page 109 [11]

Inspection result
See page 110 [12]

Finish

- 102 -
INSPECTION

[1] Recording the pump and GE serial


numbers
(1) Read and record the 10 digit pump serial
number.
Advice
It is easier to read the pumps serial number
Pump serial number
before beginning Preparation.
Note:
Serial number input is used during adjustment
mode and inspection mode.
Pump serial no. under EEPROM P-VRZR- 351

(2) Read and record the 13 digit GE actuator


serial number.
Advice
It is easier to read the GE actuators serial
number before beginning Preparation.
Note:
Serial number input is used during adjustment
mode and inspection mode.
GE serial number

GE serial number
P-VRZR- 352

[2] Preparation
(1) Connect the test oil hose to the injection
pump. (Refer to page 69 for the fuel piping.)
(2) Connect the injection system piping to the
Test oil hose
Injection system piping injection pump. (Refer to page 68 for the
injection system piping.)
(3) Connect the controller assemblys wire
harness and intermediate harness to the
injection pumps connectors. (Refer to page
70 for the controller assemblys wiring.)
P-VRZR- 353
(4) Connect the ROM controllers wire harness
and intermediate harness to the injection
pumps VRZ EEPROM connector.
(5) Connect the FCV GND harness to the
controller assemblys wire harness and to
earth.
ROM harness (6) Connect the D-Sub 9 pin cable connector
COM2 COM1 (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
Controller unit the personal computer using the wire
Controller assembly harness for VRZ adjustment P-VRZR- 354 harness.

- 103 -
INSPECTION

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

P-VRZR- 355

FCV (magnet valve) ON/OFF switch (11) Connect the wire harness to the controller
Sub-switch units No 2 ECU connector.
(12) Turn the main switch on the rear of the
controller unit ON.
(13) Set the No 1 ~ No 4 changeover switch at
No 2.
(14) Turn the FCV (magnet valve) ON/OFF
switch ON to energize the magnet valve.
(15) Turn the sub switch on the front of the
ECU for VRZ type controller unit ON.
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.
MC-02 TESTER (3) Input the password and press the Enter key.
Precaution Advice
Password is required to actuate adjustment tools. Input the initial default password RBAJ or
Input password and press ENTER key.
your own password.

(3)
P-VRZR- 357

- 104 -
INSPECTION

[4] P a r t n u m b e r input and


MC-02 TESTER

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


Service tools for pump adjustment Version1.0 RBAJ
confirmation
ROM COVEC-F MITSUBISHI 12V
(1) Select the VRZ [Mitsubishi 12V] Inspection/
Inspection/adjustment

VRZ MITSUBISHI 12V


(1) adjustment button.
Inspection/adjustment

ROM COVEC-F MAZDA 12V


Inspection/adjustment

Manual operation

Workshop name registration

Exit

P-VRZR- 346

(2) When the dialog shown at left appears, input


MC-02 TESTER
Part number input the specified part number (6 digits) and
If number input is correct, select Next button.
If you need to input a different number, select Clear button.
press Enter.
(2)
(3) Input the pump part number (last 6 digits)
Specified part no. Pump serial no. (4)
(6 digits)
Pump part no.
446613

443062
(10 digits)
GE serial no.
5555555555

6666666666666 (5)
and press Enter.
(3) (last 6 digits) (13 digits)

System specifications 1. Specified part no.


Pump
(4) Input the pump serial number (10 digits) and
Engine model VRZ_4M41 Pump
OEM
Specified part no.

press Enter.
part no. type Adjustment Inspection
Rotation Right 104700-304* 003040 008040
104700-305* COVEC-F 003051 008051
Pump cylinders 4 cylinders 104700-306* MITSUBISHI 003060 008060
ECU MELCO 109144-305*
109144-306*
VRZ

104700-055* COVEC-F MAZDA


44-6613 44-8813

000550 008550
(5) Input the GEs serial number (13 digits) and
Mode Inspection
2. Pump part no.
Example:
Full pump no.
109144-3052
Input pump part no.
443052
press Enter.
104700-0551 000551

(6)
(6) Press the Next key.
Menu Clear Next

P-VRZR- 378

(7) Confirm that the screen changes to the


MC-02 TESTER
Setup confirmation injection system piping display.
Installation confirmation
Click on appropriate item Key no. Part name Part no. Note
and explanatory illustration is displayed. 1 Injection pipe 157808-4720
2 Nozzle & nozzle holder assembly 1 688 901 035
1. Injection system piping 3 Joint Same as VP44
4 Injection tube
2. Overflow piping

3. Adjustment controller wiring

4. Operation sequence 3

2 4

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

Back Next

P-VRZR- 359

- 105 -
INSPECTION

Service tools for pump adjustment Adjustment display


Status Item Measured / input value Unit Specification Tolerance
[5] Warming-up operation
Pump information

N 0 r/min
Specified part no.

Pump part no.


44-8813

44-3052
(1) Set the pump test bench delivery pressure
at the specified 40 kPa {0.4 kgf/cm2}.
Pump serial no. 5555555555
T 0.0 deg C GE serial no. 66666-666-66666
(4) Engine model VRZ_4M41
Ua-ist V Rotation

Pump cylinders
Right
4 cylinders
(2) Confirm that the sequence is Step 01/26.
Q 0.0 mm3/st ECU

Mode
MELCO

Adjustment
(3) Run the injection pump at the specified
Pump type VRZ (12V)
speed N (see figure at left).
02/04/03 14:07:56 (4) Measure N, T and Q on the pump test bench
Menu Part number input

Step information
Present step
No. Step name N Soll Soll-cor Frequency Duty
and input the values.
(5) Step status 01 Warm-up 300r/min 2.80v 0.00mv 60Hz 100%

Next
Comment Check for fuel leaks.
Note:
U ist is displayed automatically.
(6) Sequence 01 / 26 After values are input, push Next button.
Select 02 Warm-up 1000r/min 2.91v 0.00mv 60Hz 100%

(2)
(5) Confirm that the Step status field is green.
P-VRZR- 379
(6) Proceed to the next step.
Advice
If U ist values are not as specified, press
the Next button several times. Then, return
to Step 01/26 using the back arrow.
Repeat the Step 01/26 and confirm that U
ist values are as specified.
Note:
If not as specified after confirming U ist several
times, the GE may be faulty.

Service tools for pump adjustment Adjustment display


(7) Confirm that the sequence is Step 02/26.
Status Item

N
Measured / input value

0 r/min
Unit Specification Tolerance Pump information
Specified part no.

Pump part no.


44-8813

44-3052
(8) Run the injection pump at the specified
T 0.0 deg C
Pump serial no.

GE serial no.
5555555555
66666-666-66666
speed N (see figure at left).
(9)
Ua-ist V
Engine model

Rotation
VRZ_4M41
Right
(9) Measure N, T and Q on the pump test bench
Pump cylinders 4 cylinders

Q 0.0 mm3/st ECU

Mode
MELCO

Adjustment
and input the values.
Pump type VRZ (12V)
Note:
02/04/03 14:09:35
U ist is displayed automatically.
Step information
No. Step name N Soll
Menu

Soll-cor
Part number input

Frequency Duty
(10) Confirm injection.
(13)
Step status Present step
Comment
02
Warm-up
Warm-up 1000r/min 2.91v 0.00mv 60Hz 100%
(11) Confirm that no fuel leaks from the
Next
(14) Sequence

Select
02 / 26

03
After values are input, push Next button.
P-cham_ADJ 1000r/min 2.91v 0.00mv 60Hz 100%
injection pump fuel piping connections.
(7) P-VRZR- 380 CAUTION
If there are any fuel leaks, if there is no
injection or if any unusual noises occur
during operation, stop test bench operation
immediately and inspect the pump.
(12) Confirm that the injection pump is
operating normally.
(13) Confirm that the Step status field is green.
(14) Proceed to the next step.
Advice
Because the test oil temperature takes
longer to increase in cold weather, turn the
pump test bench on earlier.

- 106 -
INSPECTION

Service tools for pump adjustment Adjustment display


Status Item Measured / input value Unit Specification Tolerance
[6] P u m p c h a m b e r pressure
Pump information

N 0 r/min
Specified part no.

Pump part no.

Pump serial no.


44-8813

44-3052 confirmation
5555555555
T 0.0 deg C GE serial no. 66666-666-66666
(1) Confirm that the sequence is Step 03/26.
(3) Engine model VRZ_4M41
Ua-ist V Rotation

Pump cylinders
Right
4 cylinders
(2) Run the injection pump at the specified
Pt 0.000 MPa ECU

Mode
MELCO

Adjustment speed N (see figure at left).


Qo 0.0 I/h Pump type

(3) Measure N, T, Pt and Qo on the pump test


VRZ (12V)

TF V
Menu
02/04/03 14:10:05
Part number input
bench and input the values.
Step information
Present step
No. Step name N Soll Soll-cor Frequency Duty Note:
(5)
U ist and Tf are displayed automatically.
Step status 03 P-cham_ADJ 1000r/min 2.91v 0.00mv 60Hz 100%
Comment Reconfirm PT standard point.
Next
(6) Sequence 03 / 26 After values are input, push Next button.
Select 04 Zero_set 500r/min 2.50v 0.00mv 60Hz 100% (4) Confirm the pump chamber pressure.
(1) P-VRZR- 386
(5) Confirm that the Step status field is green.
(6) Proceed to the next step.
Service tools for pump adjustment Adjustment display
[7] TPS confirmation
Status Item Measured / input value Unit Specification Tolerance Pump information

N 0 r/min
Specified part no.

Pump part no.


44-6613

44-3062
(1) Confirm that the sequence is Step 04/26.
(3)
T 0.0 deg C
Pump serial no.

GE serial no.
0880052496
50620-088-52056 (2) Run the injection pump at the specified
speed N (see figure at left).
Engine model VRZ_4M41
Ua-ist V Rotation Right
Pump cylinders 4 cylinders

VTPS V ECU

Mode
MELCO

Adjustment
(3) Measure N and T on the pump test bench
TPS V Pump type VRZ (12V)
and input the values.
(4) 05/04/03 14:10:51
Note:
U ist, VTPS and TPS are displayed
Zero set Menu Part number input

Step information
No. Step name N Soll Soll-cor Frequency Duty
Present step
(5) Step status
Comment
04 Zero_set
Push Zero set button.
500r/min 2.50v 0.00mv 60Hz 0%

automatically.
Next
(6)
(4) Press the Zero set key and confirm that the
Sequence 04 / 26 After values are input, push Next button.
Select 05 Timer_TA 100r/min 2.41v 0.00mv 60Hz 0%

(1)
VTPS value is within the specifications.
P-VRZR- 387
(5) Confirm that the Step status field is green.
(6) Proceed to the next step.

Service tools for pump adjustment Adjustment display


[8] Timer stroke confirmation
Status Item

N
Measured / input value

0 r/min
Unit Specification Tolerance Pump information
Specified part no.

Pump part no.


44-6613

44-3062
(1) Confirm that the sequence is Step 05/26.
T 0.0 deg C
Pump serial no.

GE serial no.
0880052496
50620-088-52056
(2) Run the injection pump at the specified
(3)
Ua-ist V
Engine model

Rotation
VRZ_4M41
Right
speed N (see figure at left).
4 cylinders

(3) Measure N, T and Pt on the pump test bench


Pump cylinders

Pt 0.000 MPa ECU MELCO

Mode Adjustment

VTPS V Pump type VRZ (12V)


and input the values.
TA mm
05/04/03 14:11:50
Note:
Step information
No. Step name N Soll
Menu

Soll-cor
Part number input

Frequency Duty
U i s t , V T P S a n d TA a r e d i s p l a y e d
(5) Step status Present step
Comment
05
100r/min
Timer_TA 100r/min 2.41v 0.00mv 60Hz 100%
automatically.
Next
(6) Sequence 05 / 26 After values are input, push Next button.
(4) Confirm that the timer stroke TA is within
Select 06 Timer_TA 50r/min 2.41v 0.00mv 60Hz 100%

(1)
the specifications.
P-VRZR- 388
(5) Confirm that the Step status field is green.
(6) Proceed to the next step.

- 107 -
INSPECTION

Service tools for pump adjustment Adjustment display


Confirm 50 revolutions (Step 06/26) ~ 1,900
Status Item

N
Measured / input value

0 r/min
Unit Specification Tolerance Pump information
Specified part no. 44-6613 revolutions (Step 14/26) using the same
Pump part no. 44-3062

T 0.0 deg C
Pump serial no.

GE serial no.
0880052496
50620-088-52056
procedure used for 100 revolutions (Step 5/26)
Ua-ist V
Engine model

Rotation
VRZ_4M41
Right
above.
Pump cylinders 4 cylinders

Pt 0.000 MPa ECU MELCO

Mode Adjustment

VTPS V Pump type VRZ (12V)

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

Step information
No. Step name N Soll Soll-cor Frequency Duty
Step status Present step 05 Timer_TA 100r/min 2.41v 0.00mv 60Hz 100%
Comment 100r/min
Next
Sequence 05 / 26 After values are input, push Next button.
Select 06 Timer_TA 50r/min 2.41v 0.00mv 60Hz 100%

P-VRZR- 381

Service tools for pump adjustment Adjustment display


[9] Non-injection confirmation
Status Item

N
Measured / input value

0 r/min
Unit Specification Tolerance Pump information
Specified part no.

Pump part no.


44-8813

44-3052
(1) Confirm that the sequence is Step 15/26.
T 0.0 deg C
Pump serial no.

GE serial no.
5555555555
66666-666-66666
(2) Run the injection pump at the specified
(3) Ua-ist V
Engine model

Rotation
VRZ_4M41
Right
speed N (see figure at left).
Pump cylinders 4 cylinders

Q 0.0 mm /st 3 ECU

Mode
MELCO

Adjustment
(3) Measure N, T, Q and DQ on the pump test
DQ 0.0 mm3/st Pump type VRZ (12V)
bench and input the values.
02/04/03 14:13:11
Note:
Step information
No. Step name N Soll
Menu

Soll-cor
Part number input

Frequency Duty
U ist is displayed automatically.
(4) Step status Present step
Comment
15 Q_characteristics
Confirm no nozzle injection.
2300r/min 0.87v 0.00mv 60Hz 100%
(4) Confirm that the Step status field is green.
(5) Next
Sequence

Select 16
15 / 26 After values are input, push Next button.
Cor-Q_INSP 1000r/min 2.91v -34.18mv 60Hz 100%
(5) Proceed to the next step.
(1) P-VRZR- 382

Service tools for pump adjustment Adjustment display


Status Item Measured / input value Unit Specification Tolerance
[10] Injection quantity confirmation
Pump information

N 0 r/min
Specified part no.

Pump part no.


44-8813

44-3052
(1) Confirm that the sequence is Step 16/26.
(2) Run the injection pump at the specified
Pump serial no. 5555555555
T 0.0 deg C GE serial no. 66666-666-66666

Engine model VRZ_4M41


(3) Ua-ist V Rotation

Pump cylinders
Right
4 cylinders
speed N (see figure at left).
Q 0.0 mm3/st ECU

Mode
MELCO

Adjustment
(3) Measure N, T, Q and DQ on the pump test
DQ 0.0 mm3/st Pump type VRZ (12V)
bench and input the values.
02/04/03 14:13:47 Note:
U ist is displayed automatically.
Menu Part number input

Step information
No. Step name N Soll Soll-cor Frequency Duty
Step status Present step Cor-Q_INSP 100%
(4) Comment
16
Correction point 8
1000r/min 2.91v -34.18mv 60Hz

Advice
Next
(5) Sequence

Do not perform injection quantity


16 / 26 After values are input, push Next button.
Select 17 Cor-Q_INSP 1900r/min 3.73v 34.18mv 60Hz 100%

(1) adjustment.
P-VRZR- 383
(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. 44-8813
N 0 r/min Pump part no.

Pump serial no.


44-3052
5555555555 Confirm compensation point 11 (Step 17/26) ~
T 0.0 deg C GE serial no. 66666-666-66666

Ua-ist
Engine model VRZ_4M41 compensation point 1 (Step 25/26) using the
V Rotation Right

Q 0.0 mm3/st
Pump cylinders

ECU
4 cylinders
MELCO
same procedure used for compensation point
DQ 0.0 mm3/st
Mode

Pump type
Adjustment

VRZ (12V) 10 (Step 16/26) above.


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

Step information
No. Step name N Soll Soll-cor Frequency Duty
Step status Present step 16 Cor-Q_INSP 1000r/min 2.91v -34.18mv 60Hz 100%
Comment Correction point 8
Next
Sequence 16 / 26 After values are input, push Next button.
Select 17 Cor-Q_INSP 1900r/min 3.73v 34.18mv 60Hz 100%

P-VRZR- 383

- 108 -
INSPECTION

Service tools for pump adjustment Adjustment display


Status Item Measured / input value Unit Specification Tolerance Pump information
[11] M a g n e t v a l v e o p e r a t i o n
44-8813

confirmation
Specified part no.
N 0 r/min Pump part no. 44-3052
Pump serial no. 5555555555

(3) T 0.0 deg C GE serial no.

Engine model
66666-666-66666

VRZ_4M41
(1) Confirm that the sequence is Step 26/26.
Ua-ist V Rotation

Pump cylinders
Right
4 cylinders (2) Run the injection pump at the specified
Q 0.0 mm3/st ECU MELCO

Mode

Pump type
Adjustment

VRZ (12V)
speed N (see figure at left).
(3) Measure N, T and Q on the pump test bench
Menu
02/04/03 14:14:59
Part number input
and input the values.
Step information
Step status Present step
No.
26 Stop_Q
Step name N
1000r/min
Soll
2.91v
Soll-cor
0.00mv
Frequency
60Hz
Duty
100%
Note:
U ist is displayed automatically.
Comment Confirm no nozzle injection when the FCV is OFF.
Next
Sequence 26 / 26 After values are input, push Next button.
Select _
Inspection finished

(1) P-VRZR- 384

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

P-VRZR- 356

Service tools for pump adjustment Adjustment display


(5) Measure N, T and Q on the pump test bench
Status Item

N
Measured / input value

0 r/min
Unit Specification Tolerance Pump information
Specified part no.

Pump part no.


44-8813

44-3052
and input the values.
T 0.0 deg C
Pump serial no.

GE serial no.
5555555555
66666-666-66666
(6) Confirm that the Step status field is green.
(5)
Ua-ist V
Engine model

Rotation
VRZ_4M41
Right
(7) Proceed to the next step.
Pump cylinders 4 cylinders

Q 0.0 mm3/st ECU MELCO

Mode Adjustment
Pump type VRZ (12V)

02/04/03 14:14:59
Menu Part number input

Step information
No. Step name N Soll Soll-cor Frequency Duty

(6) Step status Present step


Comment
26 Stop_Q
Confirm no nozzle injection when the FCV is OFF.
1000r/min 2.91v 0.00mv 60Hz 100%

Next
(7) Sequence 26 / 26 After values are input, push Next button.
Select _
Inspection finished

P-VRZR- 384

- 109 -
INSPECTION

MC-02 TESTER
[12] Inspection result
Specified part no. 44-8813
Inspection result
Pump serial no. 5555555555 Test complete Adjustment necessary
(1) Click the Next key.
44-3052 66666-666-66666
(2) The message Do you want to print and save
Pump part no. GE serial no.

ECU values Measured values


No. Result Step name N Uasoll Soll-cor TCVF DTCV N T Uaist Q DQ Pt Qo VTPS TA TPS TF
r/min V mv Hz % r/min DegC v mm /st mm /st MPa I/h v mm V V
1 Warm-up 300 2.80 0.00 60 100 0 0.0 2.80 0.0
2
3
4
5
Warm-up
P-cham_ADJ
Zero_set
Timer_TA
1000
1000
500
100
2.91
2.91
2.50
2.41
0.00
0.00
0.00
0.00
60
60
60
60
100
100
0
100
0
0
0
0
0.0
0.0
0.0
0.0
2.90
2.91
2.50
2.41
0.0
0.000
0.000
0.0
0.78
0.78 2.80
0.78
0.00 test record appears.
(3) Click OK.
6 Timer_TA 50 2.41 0.00 60 100 0 0.0 2.41 0.000 0.78 2.80
7 Timer_TA 325 1.53 0.00 60 0 0 0.0 0.00 0.000 0.00 0.00
8 Timer_TA 375 1.53 0.00 60 100 0 0.0 0.00 0.000 0.00 0.00
9 Timer_TA 375 1.53 0.00 60 100 0 0.0 1.52 0.000 0.78 2.80
10 Timer_TA 500 1.53 0.00 60 0 0 0.0 1.52 0.000 0.78 2.80
11
12
13
14
15
Timer_TA
Timer_TA
Timer_TA
Timer_TA
Q_characteristics
1000
1000
1900
1900
2300
2.91
2.91
3.73
3.73
0.87
0.00
0.00
0.00
0.00
0.00
60
60
60
60
60
100
100
100
0
0
0.0
0.0
Do you want0 to print0.0
100
100 OK 0
0
and save
0.0
0.00
0.00
0.00
test record?
0.00
0.0Cancel 0.00
0.0
0.0 0.0
0.000
0.000
0.000
0.000
0.77
0.78
0.76
0.76
2.76
2.80
2.72
2.72
Note:
16
17
18
19
Cor-Q_INSP
Cor-Q_INSP
Cor-Q_INSP
Cor-Q_INSP
1000
1900
2300
600
2.91 -34.18
3.73 34.18
1.93 -14.65
2.20 58.59
60
60
60
60
100
100
100
100
0
0
0
0
0.0
0.0
0.0
0.0
0.00
3.76
1.91
2.26
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
If you select Cancel, you cannot continue to
20 Cor-Q_INSP 600 1.86 -43.95 60 100 0 0.0 2.26 0.0 0.0
21
22
23
24
Cor-Q_INSP
Cor-Q_INSP
Cor-Q_INSP
Cor-Q_INSP
375
375
325
325
1.86 -63.48
1.53 -63.48
1.86 -53.71
1.53 -63.71
60
60
60
60
100
100
100
100
0
0
0
0
0.0
0.0
0.0
0.0
0.00
0.00
0.00
0.00
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
the next step.
25 Cor-Q_INSP 100 2.41 136.72 60 100 0 0.0 2.54 0.0 0.0
26
27
28
Stop_Q 1000 2.91 0.00 60 100 0 0.0 2.90 0.0
Advice
If no further measurements are required, select Next button.
To repeat a measurement, select Repeat button and input step number.
Step number Repeat Next The printed test record can be given to
(1)
the customer.
P-VRZR- 385
The saved test record is a record of all
the data and must be handled carefully.
(4) Turn the controller units sub-switch OFF.
(5) Turn the controller units main switch OFF.

- 110 -
TIGHTENING TORQUES

Units: Nm {kgfm}
P-VRZR- 389

- 111 -
PART NUMBER EXPLANATION

1. INJECTION PUMP ASSEMBLY NUMBER


1 0 9 1 * * - * * * *
(1) (2) (3) (4) (5) (6)
(1): VRZ type injection pump
(2): Number of cylinders
0 spare 1 spare 2 spare
3 3 cylinders 4 4 cylinders 5 5 cylinders
6 6 cylinders 7 spare 8 spare
9 master pump
(3): Number of plungers - diameter
0 2 - 6.5 1 2 - 7 2 2 - 7.5
3 2 - 8 4 2 - 8.5 5 2 - 9
6 spare 7 spare 8 spare
9 spare
(4): Engine manufacturer
0 Mazda 1 Isuzu 2 Nissan (Motor)
3 Mitsubishi (Motors) 4 Nissan (Diesel), Komatsu, others 5 spare
6 spare 7 spare 8 spare
9 spare
(5): Proper number
Design sequence starting from 00 with each change in the first seven digits.
(6): Suffix

2. BOSCH TYPE NUMBER


NP - VRZ - * / ** E **** R NP * * *
(1) (2) (3) (4) (5) (6) (7) (8)

(1): Manufactured by Bosch Automotive Systems Corporation


(2): VRZ type injection pump
(3): Number of cylinders
(4): Plunger diameter
(5): Electronic governor
(6): Maximum controlled governor speed (r/min)
(7): 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