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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

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2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
VRZ Training
Fuel circuit

04/22/2004 RBJP/TSS3 (konT)


2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
VRZ Training
Radial plunger high pressure pump

04/22/2004 RBJP/TSS3 (konT)


2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
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?

04/22/2004 RBJP/TSS3 (konT)


2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
VRZ Training
Fuel filling process

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


at fuel filling.

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2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
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.

04/22/2004 RBJP/TSS3 (konT)


2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
VRZ Training
Fuel injection quantity adjustment mechanism

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2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
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?

04/22/2004 RBJP/TSS3 (konT)


2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
VRZ Training
Timing link shaft

Q: Why is the timing link shaft necessary?

04/22/2004 RBJP/TSS3 (konT)


2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
VRZ Training
Timer piston sensor

Q: What is the purpose of the TPS?

04/22/2004 RBJP/TSS3 (konT)


2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
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

04/22/2004 RBJP/TSS3 (konT)


2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
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

04/22/2004 RBJP/TSS3 (konT)


2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
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

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2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
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.
04/22/2004 RBJP/TSS3 (konT)
2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
VRZ Training
Disassembly

Installing the holder Removing the feed pump Installing the cover
1
1

1. 157928-4320 1. 157928-4800
2. 157928-4320

04/22/2004 RBJP/TSS3 (konT)


2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
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

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2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
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

04/22/2004 RBJP/TSS3 (konT)


2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
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
04/22/2004 RBJP/TSS3 (konT)
2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
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.
04/22/2004 RBJP/TSS3 (konT)
2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
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

04/22/2004 RBJP/TSS3 (konT)


2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
VRZ Training
Adjustment ( pre-stroke)
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

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2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
VRZ Training
Adjustment ( pre-stroke)

Fixing the fixing bolts Installing the shim, ring and plug Installing the TCV

Installing the cover Installing the TPS

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2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
VRZ Training
Adjustment ( pre-stroke)

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.

04/22/2004 RBJP/TSS3 (konT)


2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
VRZ Training
Adjustment

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)
2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
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

04/22/2004 RBJP/TSS3 (konT)


2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
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.
04/22/2004 RBJP/TSS3 (konT)
2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
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.
04/22/2004 RBJP/TSS3 (konT)
2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
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.
04/22/2004 RBJP/TSS3 (konT)
2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
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

04/22/2004 RBJP/TSS3 (konT)


2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
VRZ Training
Adjustment

Fixing the bracket Making the aligning mark

Removing the pipe assembly and


Printing the adjustment results
installing the parts

04/22/2004 RBJP/TSS3 (konT)


2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
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

04/22/2004 RBJP/TSS3 (konT)


2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
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

04/22/2004 RBJP/TSS3 (konT)


2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
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.

04/22/2004 RBJP/TSS3 (konT)


2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
VRZ Training
Manual operation

Selecting the manual operation Inputting the target values

Select the ECU type

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2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
VRZ Training
Tightening torque

Units : N-m {kgf-m}

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2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.
VRZ Training
End of the presentation

Thank you very much for your interest and attention.

04/22/2004 RBJP/TSS3 (konT)


2004. Bosch K.K. All rights reserved.
and are registered trademarks of Robert Bosch GmbH.