Q: Which VRZ and COVEC-F Mechanism and Control System Are Similar? Which Are Different?

VRZ Training
Outline
3
Q: Which VRZ and COVEC-F mechanism

and control system are similar?
Which are different?
04/22/2004 RBJP/TSS3 (konT)

2004. Bosch K.K. All rights reserved.
and
are registered trademarks of Robert Bosch GmbH.
A: The VRZ pump utilizes the same type of

position control mechanism as the
COVEC-F pump. The VRZ pumps
mechanism to generate high pressure
injection is different from that of the
COVEC-F pump. Control is performed
electronically in the VRZ pump, utilizing the
same types of actuators as the COVEC-F
pump.
VRZ Training
Fuel circuit

and
VRZ Training
Radial plunger high pressure pump

and
VRZ Training
Type of radial plungers, control sleeve & rotor
shaft
Q: How many suction spill ports are used

during the fuel filling process for 4-and
6 cylinder pumps?
A: 4 ports for 4-cylinder pumps, 3 ports for
6-cylinder pumps.

and
VRZ Training
Fuel filling process
Q: Explain the relative position of each suction-spill port

at fuel filling.
A: The suction-spill ports of the rotor and the control
sleeve are connected.
and
VRZ Training
Compression & pressure delivery of fuel
Q: Explain the state of the suctionspill ports and discharge ports

at compression and pressure
delivery of fuel.
A: Both discharge ports are connected.
Both suction-spill ports are isolated.
and
VRZ Training
End of compression

and
VRZ Training
Fuel injection quantity adjustment
mechanism

and
VRZ Training
Control of injection timing
Q: When the injection timing is advanced, in what direction

is the timer piston moved and the cam ring rotated?
A: The timer piston is moved in the direction to compress the
timer spring, and the cam ring is rotated in the direction
opposite to that of pump rotation.
and
VRZ Training
Timing link shaft
Q: Why is the timing link shaft necessary?

A: To move the cam ring and the control sleeve
through the same phase to avoid changing
the fuel quantity and the injection rate.
and
VRZ Training
Timer piston sensor
Q: What is the purpose of the TPS?

A: To detect the timer position and to send this
information to the CPU.

and
VRZ Training
Disassembly
Removing the nut
Removing the gear
Removing the key
1. 157917-4620
1.157927-4500
Removing the nuts and cover
Installing the pump

1
1.157945-2020
and
Removing the bracket bolts
VRZ Training
Disassembly
Removing the FCV
Removing the GE actuator
Removing the regulating valve

1
1. 157913-7000
Removing the TCV

and
Removing the TPS
Removing the cover
VRZ Training
Disassembly
Removing the delivery valve
Removing the plug, ring and shim
Removing the fixing bolts
Removing the fixing bolts and plate
Removing the rotor shaft with rollers

and roller shoes
1. 157914-3600
Removing the head
1. 157971-0500
and
VRZ Training
Disassembly
Removing the ring
Removing the drive shaft
Removing the cam ring
1. 157928-6020
Removing the timer piston
Removing the bearing

1
1. 157928-3620
and
Removing the fixing bolts, cover

and O-ring
After removing the cover, remove

the o-ring.
VRZ Training
Disassembly
Installing the holder
Removing the feed pump
Installing the cover
1
1
2
1. 157928-4320

and
1. 157928-4800
2. 157928-4320
VRZ Training
Reassembly
Installing the feed pump
Installing the guide and screw in

the set screw
Installing the o-ring and cover

1
1
1. 157928-4320
1. 157928-4500 2. 157928-4200
The tool(157928-4200) makes the
centering the cover.
Fixing the fixing bolts
Installing the seal ring
Installing the bearing
1. 157928-3620
and
VRZ Training
Reassembly
Installing the timer piston
Installing the cam ring
Pulling the bearing

1
1. 157928-3620
Pull the bearing until the groove for the

ring is found.
Installing the spacer
Install the drive shaft
Remove the spacer
1. 157928-4700
and
1. 157928-4700
VRZ Training
Reassembly
Install the ring
Installing the head
Measuring the drive shaft axial play

1
1. 157928-3120
Assemble the distributor head without

rotor shaft and the control sleeve.
Adjusting shim for axial play
Removing the head
1. 105782-4530
Standard (specified) value :
0.1 +/- 0.05 mm
Measuring the rotor shaft axial play
Adjusting shim
Standard (specified) value :

0.2 +/- 0.1 mm
and
VRZ Training
Reassembly and Adjustment ( pre-stroke)
Adjusting shim for axial play
Installing the TPS
Adjusting shim
Removing the pump
Installing the pump
Adjusting the drive shaft position

Drive shaft key
position
View from drive shaft
Adjust the drive shaft position so that

the key groove is B cylinder.
and
VRZ Training
Adjustment ( pre-stroke)
Relationship between the cam lift and cam angle.
Cam lift
Installing the measuring device
Measuring terminal
The measuring terminal

must be B cylinder position.
1) The dial gauge

zero setting point
4) 5 degrees
2) 0.7mm cam lift point.
3) the display zero
setting point
0.7
degree
5)The display zero setting point
Cam beginning of lift point
Setting the dial gauge at zero position Setting the plunger lift at 0.7mm
Set the dial gauge at zero position

when the B cylinder is in the BDC.
and
Set the plunger lift at 0.7mm
Setting display at the zero
VRZ Training
Setting the cam angle at 355
degree
Resetting the display at the zero
Removing the tool and parts
Installing the rotor shaft
Installing the head
355
Installing the plate

and
VRZ Training
Fixing the fixing bolts
Installing the shim, ring and plug
Installing the TPS

and
Installing the TCV
VRZ Training
Installing the FCV
Preparation for the pre-stroke
Install the hose and tool.

Close the overflow by plug.
Measuring the pre-stroke
Turn the pump slowly.

and
Adjusting part
Measuring the pre-stroke
Supply the fuel.
VRZ Training
Adjustment
Injection piping diagram
Fuel piping diagram
Controller wiring
Flow chart
Operating the PC
Inputting the password
Initial default password is RBAJ

and
VRZ Training
Adjustment
Selecting the VRZ
Inputting the each numbers
Pump serial number
Adjustment : 446704
inspection : 448904
GE serial number
Confirming the test condition

and
Worming up
VRZ Training
Adjustment
Adjusting the pump chamber pressure
Adjusting the basis injection quantity
Adjust the pump chamber pressure using the regulating valve.

Do not disassemble the regulating valve to readjusting.
Adjusting and confirming the TPS output signal
shim
Adjust the injection quantity moving the
GE actuator.
Adjusting the TPS output signal using

the shim. After that, click the zero setting
tab.

and
VRZ Training
Adjustment
Injection quantity compensation point
adjustment
Adjusting the timer stroke
shim
Adjust the injection quantity using the
Adjust the timer stroke using the shim. revision value
Compensation ROM calculation Confirming the magnet valve operation
After setting the pump speed, turn the magnet valve power switch off. Confirm that
injection quantity will remain zero. Do not take long time for this confirmation.
Because, the rotor shaft may be damaged.
and
VRZ Training
Adjustment
Second timing adjustment
Power off the controller
Removing the pump
Installing the o-ring and bracket
Fixing the nut
Attaching the pump
Fix the bracket using the nuts

temporarily.
Hold the gear using the tool and fix the nut.

and
VRZ Training
Adjustment
Installing the adjusting device
Connecting the cable and hose
Power on
Adjusting the bracket position
Fixing the drive shaft
Standard tooth must be installed

to the rack

and
VRZ Training
Adjustment
Making the aligning mark
Fixing the bracket
Printing the adjustment results
Removing the pipe assembly and

installing the parts

and
VRZ Training
Inspection
Selecting the VRZ
Inputting the each numbers
Pump serial number
Adjustment : 446704
inspection : 448904
GE serial number
Confirming the test condition

and
Worming up
VRZ Training
Inspection
Confirming the pump chamber
pressure
Worming up
Confirming the TPS output signal
After confirming the TPS output

signal, crick the zero setting tab.
Confirming the timer stroke
Confirming the no injection quantity

and
Confirming the injection quantity
VRZ Training
Inspection
Confirming the magnet valve
operation
After setting the pump speed, turn the magnet valve power switch off. Confirm that
injection quantity will remain zero. Do not take long time for this confirmation.
Because, the rotor shaft may be damaged.

and
Printing the adjustment results
VRZ Training
Manual operation
Selecting the manual operation
Inputting the target values
Select the ECU type

and
VRZ Training
Tightening torque
Units : N-m {kgf-m}

and
VRZ Training
End of the presentation
Thank you very much for your interest and attention.

and

Q: Which VRZ and COVEC-F Mechanism and Control System Are Similar? Which Are Different?

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VRZ Training

Q: Which VRZ and COVEC-F mechanism

04/22/2004 RBJP/TSS3 (konT)

A: The VRZ pump utilizes the same type of

04/22/2004 RBJP/TSS3 (konT)

04/22/2004 RBJP/TSS3 (konT)

Q: How many suction spill ports are used

04/22/2004 RBJP/TSS3 (konT)

Q: Explain the relative position of each suction-spill port

Q: Explain the state of the suctionspill ports and discharge ports

04/22/2004 RBJP/TSS3 (konT)

04/22/2004 RBJP/TSS3 (konT)

Q: When the injection timing is advanced, in what direction

Q: Why is the timing link shaft necessary?

Q: What is the purpose of the TPS?

04/22/2004 RBJP/TSS3 (konT)

Removing the gear

Removing the key

Removing the nuts and cover

Installing the pump

Removing the bracket bolts

Removing the GE actuator

Removing the regulating valve

Removing the TCV

04/22/2004 RBJP/TSS3 (konT)

Removing the TPS

Removing the cover

Removing the plug, ring and shim

Removing the fixing bolts

Removing the fixing bolts and plate

Removing the rotor shaft with rollers

Removing the head

Removing the drive shaft

Removing the cam ring

Removing the timer piston

Removing the bearing

Removing the fixing bolts, cover

After removing the cover, remove

Removing the feed pump

Installing the cover

04/22/2004 RBJP/TSS3 (konT)

Installing the guide and screw in

Installing the o-ring and cover

Fixing the fixing bolts

Installing the seal ring

Installing the bearing

Installing the cam ring

Pulling the bearing

Pull the bearing until the groove for the

Installing the spacer

Install the drive shaft

Remove the spacer

Installing the head

Measuring the drive shaft axial play

Assemble the distributor head without

Adjusting shim for axial play

Removing the head

Standard (specified) value :

Installing the TPS

Installing the cover

Removing the pump

Installing the pump

Adjusting the drive shaft position