Ajuste de Bomba VRZ

VRZ Training
Outline
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.
VRZ Training
End of compression

VRZ Training
Fuel circuit

VRZ Training
Radial plunger high pressure pump

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

during the fuel filling process for 4-and
6 cylinder pumps?

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

at fuel filling.

VRZ Training
Compression & pressure delivery of fuel
Q: Explain the state of the suction-

spill ports and discharge ports
at compression and pressure
delivery of fuel.

VRZ Training
Fuel injection quantity adjustment mechanism

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?

VRZ Training
Timing link shaft
Q: Why is the timing link shaft necessary?

VRZ Training
Timer piston sensor
Q: What is the purpose of the TPS?

VRZ Training
Disassembly
Removing the nut Removing the gear Removing the key

1 1
1. 157917-4620 1.157927-4500
Removing the nuts and cover Installing the pump Removing the bracket bolts
1.157945-2020

VRZ Training
Disassembly
Removing the FCV Removing the GE actuator Removing the regulating valve
1. 157913-7000
Removing the TCV Removing the TPS Removing the cover

VRZ Training
Disassembly
Removing the delivery valve Removing the plug, ring and shim Removing the fixing bolts
1. 157914-3600
Removing the head Removing the fixing bolts and plate Removing the rotor shaft with rollers and
roller shoes
1
1. 157971-0500

VRZ Training
Disassembly
Removing the ring Removing the drive shaft Removing the cam ring
1. 157928-6020
Removing the timer piston Removing the bearing Removing the fixing bolts, cover
and O-ring
1
1. 157928-3620
After removing the cover, remove
the o-ring.
VRZ Training
Disassembly
Installing the holder Removing the feed pump Installing the cover
1
1
1. 157928-4320 1. 157928-4800
2. 157928-4320

VRZ Training
Reassembly
Installing the feed pump Installing the o-ring and cover Installing the guide and screw in
the set screw
1 2
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
1. 157928-3620

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 1
1. 157928-4700 1. 157928-4700

VRZ Training
Reassembly
Install the ring Installing the head Measuring the drive shaft axial play
1 1
1. 157928-3120 Assemble the distributor head without 1. 105782-4530

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

0.2 +/- 0.1 mm
VRZ Training
Reassembly and Adjustment ( pre-stroke)
Adjusting shim for axial play Installing the TPS Installing the cover
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.
VRZ Training
Adjustment ( pre-stroke)
Installing the measuring device Relationship between the cam lift and cam angle.
Cam lift
1) The dial gauge
zero setting point
4) 5 degrees
2) 0.7mm cam lift point.
3) the display zero
setting point
Measuring terminal
0.7
degree
The measuring terminal 5) The display zero setting point
must be B cylinder position. Cam beginning of lift point
Setting the dial gauge at zero position Setting the plunger lift at 0.7mm Setting display at the zero
Set the dial gauge at zero position

when the B cylinder is in the BDC. Set the plunger lift at 0.7mm

VRZ Training
Setting the cam angle at 355 Resetting the display at the zero Removing the tool and parts
degree
355
Installing the plate Installing the rotor shaft Installing the head

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

VRZ Training
Installing the FCV Preparation for the pre-stroke Measuring the pre-stroke
Install the hose and tool. Supply the fuel.

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

VRZ Training
Adjustment
Injection piping diagram Fuel piping diagram Controller wiring
Flow chart Operating the PC Inputting the password
Initial default password is RBAJ

VRZ Training
Adjustment
Selecting the VRZ Inputting the each numbers Pump serial number
Adjustment : 446704
inspection : 448904
GE serial number Confirming the test condition 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
Adjusting the TPS output signal using the

Adjust the injection quantity moving the
shim. After that, click the zero setting tab.
GE actuator.
VRZ Training
Adjustment
Adjusting the timer stroke Injection quantity compensation point

adjustment
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.
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 Hold the gear using the tool and fix the nut.
temporarily.
VRZ Training
Adjustment
Installing the adjusting device Connecting the cable and hose Power on
Standard tooth must be installed

to the rack
Adjusting the bracket position Fixing the drive shaft

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

Printing the adjustment results
installing the parts

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

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

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

VRZ Training
Inspection
Confirming the magnet valve Printing the adjustment results
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.

VRZ Training
Manual operation
Selecting the manual operation Inputting the target values
Select the ECU type

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

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


Ajuste de Bomba VRZ

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VRZ Training

Q: Which VRZ and COVEC-F mechanism

04/22/2004 RBJP/TSS3 (konT)

04/22/2004 RBJP/TSS3 (konT)

04/22/2004 RBJP/TSS3 (konT)

04/22/2004 RBJP/TSS3 (konT)

Q: How many suctionspill ports are used

04/22/2004 RBJP/TSS3 (konT)

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

04/22/2004 RBJP/TSS3 (konT)

Q: Explain the state of the suction-

04/22/2004 RBJP/TSS3 (konT)

04/22/2004 RBJP/TSS3 (konT)

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

04/22/2004 RBJP/TSS3 (konT)

Q: Why is the timing link shaft necessary?

04/22/2004 RBJP/TSS3 (konT)

Q: What is the purpose of the TPS?

04/22/2004 RBJP/TSS3 (konT)

Removing the nut Removing the gear Removing the key

04/22/2004 RBJP/TSS3 (konT)

Removing the TCV Removing the TPS Removing the cover

04/22/2004 RBJP/TSS3 (konT)

04/22/2004 RBJP/TSS3 (konT)

04/22/2004 RBJP/TSS3 (konT)

1. 157928-4320 1. 157928-4500 2. 157928-4200

04/22/2004 RBJP/TSS3 (konT)

04/22/2004 RBJP/TSS3 (konT)

1. 157928-3120 Assemble the distributor head without 1. 105782-4530

Standard (specified) value :

Drive shaft key

View from drive shaft

Adjust the drive shaft position so that

Set the dial gauge at zero position

04/22/2004 RBJP/TSS3 (konT)

04/22/2004 RBJP/TSS3 (konT)

Installing the cover Installing the TPS

04/22/2004 RBJP/TSS3 (konT)

Install the hose and tool. Supply the fuel.

Measuring the pre-stroke Adjusting part

Turn the pump slowly.

04/22/2004 RBJP/TSS3 (konT)

Injection piping diagram Fuel piping diagram Controller wiring

Flow chart Operating the PC Inputting the password

Initial default password is RBAJ

04/22/2004 RBJP/TSS3 (konT)

Adjust the pump chamber pressure using the regulating valve.

Adjusting and confirming the TPS output signal

Adjusting the TPS output signal using the

Adjusting the timer stroke Injection quantity compensation point

Adjust the injection quantity using the

Compensation ROM calculation Confirming the magnet valve operation

Standard tooth must be installed

04/22/2004 RBJP/TSS3 (konT)

Fixing the bracket Making the aligning mark

Removing the pipe assembly and

04/22/2004 RBJP/TSS3 (konT)

04/22/2004 RBJP/TSS3 (konT)

After confirming the TPS output

04/22/2004 RBJP/TSS3 (konT)

04/22/2004 RBJP/TSS3 (konT)

Selecting the manual operation Inputting the target values

Select the ECU type