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Documente Profesional
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EE14E-11162
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.
Injection pump
P-VRZR- 320
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
Wire harness
Injection pump
P-VRZR- 323
-1-
SPECIAL TOOLS
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
-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
-5-
SPECIAL TOOLS
46
25 75
-6-
SPECIAL TOOLS
-7-
SPECIAL TOOLS
-8-
SPECIAL TOOLS
2. ADJUSTMENT TOOLS
[1] Tool use locations
9
8
7
2
4
3
P-VRZR- 325
-9-
SPECIAL TOOLS
Note:
Center height is the height from the center of the pump test benchs flywheel to the drive stand.
- 10 -
SPECIAL TOOLS
200
M12X1.5
11
M10X1.0
- 11 -
SPECIAL TOOLS
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.
- 12 -
SPECIAL TOOLS
1-1 157966-4020
(9 443 613 446)
CONTROLLER ASSY
2000
2000
1000
2000
2990
- 13 -
SPECIAL TOOLS
1-3 157966-3820
(9 443 613 457)
ECU assembly (4M41)
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
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.
- 16 -
DISASSEMBLY
Sub-gear
P-VRZR- 302
P-VRZR- 303
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
Key
Drive shaft
P-VRZR- 307
Nuts (3)
O-ring
P-VRZR- 319
- 18 -
DISASSEMBLY
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
Bracket C
P-VRZR- 309
Bracket bolts
P-VRZR- 310
- 19 -
DISASSEMBLY
P-VRZR- 020
Advice
Do not remove the GE cover.
P-VRZR- 021
P-VRZR- 022
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
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
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.
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
P-VRZR- 029
P-VRZR- 030
Plug
P-VRZR- 031
P-VRZR- 032
- 23 -
DISASSEMBLY
Advice
If the distributor head is not loose, tap the
sides lightly with a plastic hammer.
P-VRZR- 033
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
Advice
Do not disassemble the plunger from the
rotor shaft.
P-VRZR- 037
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
P-VRZR- 041
- 26 -
DISASSEMBLY
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
P-VRZR- 045
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
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
P-VRZR- 054
- 31 -
COMPONENT INSPECTION
Ball pin
Roller shoes
Washer
Rollers P-VRZR- 057
Timer slider
P-VRZR- 058
P-VRZR- 059
- 32 -
COMPONENT INSPECTION
Distributor head
P-VRZR- 061
Roller shoes
Rollers
P-VRZR- 062
Links pin
Plate
P-VRZR- 063
- 33 -
COMPONENT INSPECTION
Control sleeve
P-VRZR- 064
CPV holder
P-VRZR- 065
P-VRZR- 066
P-VRZR- 067
- 34 -
COMPONENT INSPECTION
P-VRZR- 069
Control sleeve
- 35 -
COMPONENT INSPECTION
P-VRZR- 313
Filter
P-VRZR- 073
TCV
P-VRZR- 074
- 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.
Reference values:
(25, 2) = (fuel temperature, resistance) Terminal Resistance
Fuel temperature (C)
nos ()
7-8 2 25
- 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
P-VRZR- 332
- 39 -
GEAR REASSEMBLY
Pin
P-VRZR- 333
P-VRZR- 334
CAUTION
Pliers
Snapring Socket head bolts cannot be reused.
Main gear
Part no
Part name Remarks
(Mitsubishi part no)
149931-1600
Base Snapring
P-VRZR- 336 (ME204236)
- 40 -
GEAR REASSEMBLY
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.
CAUTION
Bolts cannot be reused.
P-VRZR- 340
The above completes reassembly of the drive
gear for the 4M41 model engine.
- 41 -
REASSEMBLY
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
P-VRZR- 079
- 42 -
REASSEMBLY
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
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
- 43 -
REASSEMBLY
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.
P-VRZR- 084
Advice
Ensure the bearing is positioned correctly.
P-VRZR- 085
- 44 -
REASSEMBLY
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.
- 45 -
REASSEMBLY
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
P-VRZR- 091
- 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
Clip Advice
Snapring Position the snapring on the clip with the
convex face toward the clip.
Convex face
P-VRZR- 095
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
P-VRZR- 098
- 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
Extractor
P-VRZR- 101
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.
- 49 -
REASSEMBLY
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
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
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
P-VRZR- 109
Pump housing
Bracket C
P-VRZR- 110
- 51 -
REASSEMBLY
2. PRE-STROKE ADJUSTMENT
Original pre-stroke
Control sleeve
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).
- 52 -
REASSEMBLY
P-VRZR- 111
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
P-VRZR- 114
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
Dial gauge
P-VRZR- 117
- 55 -
REASSEMBLY
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
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
Distributor head
P-VRZR- 124
- 58 -
REASSEMBLY
P-VRZR- 127
Shim
Plug
P-VRZR- 128
P-VRZR- 129
- 59 -
REASSEMBLY
P-VRZR- 131
P-VRZR- 132
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
- 60 -
REASSEMBLY
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
Socket wrench
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
P-VRZR- 140
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
P-VRZR- 143
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
Armature
Gauze filter
P-VRZR- 147
P-VRZR- 148
Injection pump
Adapter 157977-8000
Gasket 026512-1640
Hose
P-VRZR- 149
P-VRZR- 150
- 64 -
REASSEMBLY
P-VRZR- 151
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
Lever
P-VRZR- 154
- 65 -
REASSEMBLY
- 66 -
REASSEMBLY
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
- 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
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
- 68 -
ADJUSTMENT
Piping outline
Pressure gauge
1/5 1/4
1/1 1/2 1/3
1/6 1/2
Multi-way cock
1/5
1/7
Test oil hose
- 69 -
ADJUSTMENT
Intermediate harness
Personal computer
(157966-2421) Intermediate harness
(157966-5720)
Dsub 9 pin
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
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
Note:
Where updating of adjustment data and inspection data is indicated, copy the data from the ESPI
(ZW)s CD-ROM.
- 71 -
ADJUSTMENT
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.
- 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.
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
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
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
ADJUSTMENT
completed) (= Item is not changed)
Print result Cancel Print result Cancel
OK
P-VRZR- 396
MC-02 TESTER
4 Manual operation
Exit
6
P-VRZR- 346
- 76 -
ADJUSTMENT
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
14 Next
Sequence 03 / 32 After values are input, push 'Next' button. 25
15 Select 04 500rpm 2.50v 60Hz 0%
P-VRZR- 347
- 77 -
ADJUSTMENT
MC-02 TESTER
Manual operation
ECU reader data
TF deg C Np r/min
Select ECU
5 ROM COVEC-F MITSUBISHI 12V VRZ MITSUBISHI 12V ROM COVEC-F MAZDA 12V
4 Menu
P-VRZR- 348
- 78 -
ADJUSTMENT
7. WORKSHOP DISPLAY
Second timing adjustment (manual operation)
Pump adjustment tools for service Workshop name registration
MC-02 TESTER
Workshop name registration
7 Menu Registration 8
P-VRZR- 350
WORKSHOP REGISTRATION
MC-02 TESTER
Manual operation
(1)
Workshop name registration
Exit
P-VRZR- 346
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
Preparation
Warming-up operation
Pre-stroke adjustment
See page 64 (9)
Non-injection confirmation
See page 88 [11]
Finish
- 80 -
ADJUSTMENT
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)
P-VRZR- 357
- 82 -
ADJUSTMENT
Manual operation
Exit
P-VRZR- 346
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
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
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
N 0 r/min
Specified part no.
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
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
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.
N
Measured / input value
0 r/min
Unit Specification Tolerance Pump information
Specified part no.
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
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%
- 84 -
ADJUSTMENT
N 0 r/min
Specified part no.
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
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
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
- 85 -
ADJUSTMENT
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
N
Measured / input value
0 r/min
Unit Specification Tolerance Pump information
Specified part no.
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
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
Next
(6) Sequence
- 86 -
ADJUSTMENT
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
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.
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)
- 87 -
ADJUSTMENT
N 0 r/min
Specified part no.
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
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
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
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
N 0 r/min
Specified part no.
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
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
N 0 r/min
Specified part no.
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
Mode
MELCO
Ua-ist V
Engine model
Rotation
VRZ_4M41
Right
Input the value only to the compensation voltage
Pump cylinders 4 cylinders
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
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%
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
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
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
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
N
Measured / input value
0 r/min
Unit Specification Tolerance Pump information
Specified part no.
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
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
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
Key
P-VRZR- 253
- 91 -
ADJUSTMENT
Drive gear
P-VRZR- 254
Round nut
P-VRZR- 255
- 92 -
ADJUSTMENT
P-VRZR- 258
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
- 93 -
ADJUSTMENT
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
Mode Adjustment
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
- 94 -
ADJUSTMENT
P-VRZR- 264
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
P-VRZR- 267
- 95 -
ADJUSTMENT
P-VRZR- 268
P-VRZR- 269
P-VRZR- 270
Q 0.0 mm3/st
(14) Confirm that the Step status field is green.
ECU MELCO
Mode Adjustment
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
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
Adjusting device
(6) Injection pump removal
(1) Remove the adjusting device from the
injection pumps drive gear.
P-VRZR- 271
- 97 -
ADJUSTMENT
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
Overflow
valve
P-VRZR- 274
Stand
(9) Remove the injection pump from the test
bench.
Injection pump
P-VRZR- 275
- 98 -
ADJUSTMENT
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.
P-VRZR- 397
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
P-VRZR- 264
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
P-VRZR- 267
P-VRZR- 268
P-VRZR- 269
- 101 -
INSPECTION
INSPECTION
Inspection sequence
Recording the pump and GE serial numbers
Preparation
Warming-up operation
TPS confirmation
See page 107 [7]
Non-injection confirmation
See page 108 [9]
Inspection result
See page 110 [12]
Finish
- 102 -
INSPECTION
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.
(3)
P-VRZR- 357
- 104 -
INSPECTION
Manual operation
Exit
P-VRZR- 346
443062
(10 digits)
GE serial no.
5555555555
6666666666666 (5)
and press Enter.
(3) (last 6 digits) (13 digits)
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
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
4. Operation sequence 3
2 4
If necessary to proceed
after confirmation, push Next button.
1
Menu
Back Next
P-VRZR- 359
- 105 -
INSPECTION
N 0 r/min
Specified part no.
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.
N
Measured / input value
0 r/min
Unit Specification Tolerance Pump information
Specified part no.
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
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
N 0 r/min
Specified part no.
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
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.
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.
N
Measured / input value
0 r/min
Unit Specification Tolerance Pump information
Specified part no.
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
Mode Adjustment
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
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
Mode Adjustment
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
N
Measured / input value
0 r/min
Unit Specification Tolerance Pump information
Specified part no.
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
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
N 0 r/min
Specified part no.
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
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
(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.
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
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
confirmation
Specified part no.
N 0 r/min Pump part no. 44-3052
Pump serial no. 5555555555
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
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
N
Measured / input value
0 r/min
Unit Specification Tolerance Pump information
Specified part no.
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
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
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.
- 110 -
TIGHTENING TORQUES
Units: Nm {kgfm}
P-VRZR- 389
- 111 -
PART NUMBER EXPLANATION
- 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