Anda di halaman 1dari 46

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 OS Windows 2000 PRO (at least Service Pack 2.0) English language version
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

[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)

Tool connection 232C cable


Connection: straight connection
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
Main harness Earth to injection pump
AC200V - 240V power source VRZ and COVEC-F 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-11020
instructions included with the controller unit.
When installing the adjustment software, refer to the installation manual included with the
2 ED14E-11010
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 α 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 pump’s 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’s


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

GE serial number
P-VRZR- 352

[2] Preparation
(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 assembly’s wire
harness and intermediate harness to the
injection pump’s connectors. (Refer to page
70 for the controller assembly’s wiring.)
(4) Connect the ROM controller’s wire harness
P-VRZR- 353
and intermediate harness to the injection
pump’s VRZ EEPROM connector.
(5) Connect the FCV GND harness to the
controller assembly’s wire harness and to
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 bench’s test oil
outlet temperature at 45°C.
(10) Set the cooling unit oil delivery pressure
lever at ‘80 kPa {0.8 kgf/cm2}’ or less.

P-VRZR- 355

FCV (magnet valve) ON/OFF switch (11) Connect the wire harness to the controller
Sub-switch unit’s No 2 ECU connector.
(12) Turn the main switch on the rear of the
controller unit ON.
(13) Set the No 1 ~ No 4 changeover switch at
No 2.
(14) Turn the FCV (magnet valve) ON/OFF
switch ON to energize the magnet valve.
(15) Turn the sub switch on the front of the
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).
If number input is correct, select Next button.
If you need to input a different number, select Clear button.
(3) Input the pump part number (last 6 digits).
(2)
(4) Input the pump serial number (10 digits).
Specified part no. 446613 Pump serial no. 0880052496 (4)
(6 digits)
Pump part no. 443062
(10 digits)
GE serial no. 5062008852056 (5) (5) Input the GE’s serial number (13 digits).
(3) (last 6 digits) (13 digits)

System specifications
Engine model VRZ_4M41
1. Specified part no.
Pump Pump
OEM
Specified part no.
(6) Press the ‘Next’ key.
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*
VRZ 44-6613 44-8813
109144-306*
104700-055* COVEC-F MAZDA 000550 008550
2. Pump part no.
Example:
Full pump no. Input pump part no.
Mode Adjustment 109144-3052 443052
104700-0551 000551

Menu Clear Next


(6)

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 α 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 α ist values are not as specified, press
the ‘Next’ button several times. Then, return
to Step 01/31 using the back arrow.
Repeat the Step 01/31 and confirm that U α
ist values are as specified.
Note:
If not as specified after confirming U α ist several
times, the GE may be faulty.

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 α 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 α 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 α 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 shaft’s
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 α 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 α 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 α 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 α 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 α 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 pump’s 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 α 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


shaft’s key groove.

Key

P-VRZR- 253

- 91 -
ADJUSTMENT

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

Drive gear

P-VRZR- 254

(4) Assemble the drive gear fixing round nut to


the drive shaft and tighten it lightly.

Round nut

P-VRZR- 255

(5) Assemble the wrench to the drive gear and


tighten the round nut (SW21) to the specified
Wrench torque using a torque wrench.
Specified torque: 167 ~ 185 N·m
{17 ~ 18.7 kgf·m}
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 stand’s 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 assembly’s main


Main harness
harness and intermediate harness to the
injection pump’s 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 device’s pin hole with the
injection pump bracket’s pin. In this position,
attach the adjusting device to the injection
pump’s bracket and fix using the bolts.
Tool name Part no Remarks
Pin Rack
Adjusting
Rack teeth 105793-0020
Pin hole device

Advice
When aligning the adjusting device’s pin hole
with the bracket’s pin, position the adjusting
P-VRZR- 263 device’s rack teeth on either side of the drive
gear’s chamfered tooth.
(4) Second timing adjustment
(1) Turn the controller unit’s sub-switch ON.
(2) Supply test oil to the injection pump at the
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 B’s
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 N·m
{2.8 ~ 3.6 kgf·m}

P-VRZR- 267

- 95 -
ADJUSTMENT

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


Specified torque: 34 ~ 39 N·m
{3.5 ~ 4.0 kgf·m}

P-VRZR- 268

(10) Mark the timing mark on the injection pump


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 N·m
{1.0 ~ 1.5 kgf·m}
(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 α 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 unit’s sub-switch OFF.
(5) Turn the controller unit’s main switch OFF.

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

P-VRZR- 271

CPV (2) Replace cylinder B’s 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 ROM’s torx bolts.
Specified torque: 2 ~ 3 N·m
Q adjustment
{0.2 ~ 0.3 kgf·m}
ROM Pump housing Tool name Part no Remarks
Bit
Holder 157915-9820
Holder P-VRZR- 393 Bit 157915-9301 T20

(7) Connect the overflow valve’s bypass hose


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

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 unit’s 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 keyboard’s ‘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 keyboard’s ‘Enter’
Menu key.
P-VRZR- 348
(8) Press the ‘TCV Frequency’ button and input
‘60’ into the field. Press the keyboard’s
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
B’s 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 N·m
{2.8 ~ 3.6 kgf·m}

P-VRZR- 267

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


Specified torque: 34 ~ 39 N·m
{3.5 ~ 4.0 kgf·m}

P-VRZR- 268

(15) Mark the timing mark on the injection pump


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 N·m
{1.0 ~ 1.5 kgf·m}
(17) Turn the test oil switch OFF.
(18) Remove the injection pump as described
in (6) Injection pump removal [steps (1) to
(10)] on pages 97 to 99.
P-VRZR- 270

- 101 -
INSPECTION

INSPECTION
Inspection sequence
Recording the pump and GE serial numbers ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

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 pump’s 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 actuator’s serial
number before beginning ‘Preparation.’
Note:
Serial number input is used during adjustment
mode and inspection mode.
GE serial number

GE serial number
P-VRZR- 352

[2] Preparation
(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 assembly’s wire
harness and intermediate harness to the
injection pump’s connectors. (Refer to page
70 for the controller assembly’s wiring.)
P-VRZR- 353
(4) Connect the ROM controller’s wire harness
and intermediate harness to the injection
pump’s VRZ EEPROM connector.
(5) Connect the FCV GND harness to the
controller assembly’s wire harness and to
earth.
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 tester’s test oil outlet
temperature at 45°C.
(10) Set the cooling unit oil delivery pressure
lever at ‘80 kPa {0.8 kgf/cm2}’ or less.

P-VRZR- 355

FCV (magnet valve) ON/OFF switch (11) Connect the wire harness to the controller
Sub-switch unit’s No 2 ECU connector.
(12) Turn the main switch on the rear of the
controller unit ON.
(13) Set the No 1 ~ No 4 changeover switch at
No 2.
(14) Turn the FCV (magnet valve) ON/OFF
switch ON to energize the magnet valve.
(15) Turn the sub switch on the front of the
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).
If number input is correct, select Next button.
If you need to input a different number, select Clear button.
(3) Input the pump part number (last 6 digits).
(2)
(4) Input the pump serial number (10 digits).
Specified part no. Pump serial no. (4)
(6 digits)
Pump part no.
446613

443062
(10 digits)
GE serial no.
5555555555

6666666666666 (5)
(5) Input the GE’s serial number (13 digits).
(3) (last 6 digits) (13 digits)

System specifications 1. Specified part no.


Pump
(6) Press the ‘Next’ key.
Engine model VRZ_4M41 Pump
part no. type OEM
Specified part no.
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*
VRZ 44-6613 44-8813
109144-306*
104700-055* COVEC-F MAZDA 000550 008550
2. Pump part no.
Example:
Full pump no. Input pump part no.
Mode Inspection 109144-3052 443052
104700-0551 000551

Menu Clear Next


(6)

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 α 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 α ist values are not as specified, press
the ‘Next’ button several times. Then, return
to Step 01/26 using the back arrow.
Repeat the Step 01/26 and confirm that U α
ist values are as specified.
Note:
If not as specified after confirming U α ist several
times, the GE may be faulty.

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

- 110 -
TIGHTENING TORQUES

Units: N·m {kgf·m}


P-VRZR- 389

- 111 -
PART NUMBER EXPLANATION

1. INJECTION PUMP ASSEMBLY NUMBER


1 0 9 1 * * - * * * *
(1) (2) (3) (4) (5) (6)
(1): VRZ type injection pump
(2): Number of cylinders
0 spare 1 spare 2 spare
3 3 cylinders 4 4 cylinders 5 5 cylinders
6 6 cylinders 7 spare 8 spare
9 master pump
(3): Number of plungers - diameter
0 2 - φ6.5 1 2 - φ7 2 2 - φ7.5
3 2 - φ8 4 2 - φ8.5 5 2 - φ9
6 spare 7 spare 8 spare
9 spare
(4): Engine manufacturer
0 Mazda 1 Isuzu 2 Nissan (Motor)
3 Mitsubishi (Motors) 4 Nissan (Diesel), Komatsu, others 5 spare
6 spare 7 spare 8 spare
9 spare
(5): Proper number
Design sequence starting from ‘00’ with each change in the first seven digits.
(6): Suffix

2. BOSCH TYPE NUMBER


NP - VRZ - * / ** 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-11161
FUEL INJECTION PUMP MODEL VRZ
Service Manual
Repair Service & Maintenance
Printing: July 2003
Published by:
Bosch K.K.
Sales Automotive Aftermarket Division
Printed in Japan
C Copyright 2003, Bosch K.K.
WPGES-01