Pub. No.

EE14E-11102

SERVICE MANUAL
COVEC-F

REPAIR SERVICE
& MAINTENANCE

WARNINGS
The following definitions and warning signs are used in this service manual.
These are extremely important to safe operation.
Important points are described to prevent bodily injury and property damage.
They must be fully understood before beginning COVEC-F maintenance.

CAUTION

Improper maintenance can result in injury or property damage.

MEANINGS OF MARKS
The following marks are used in this service manual to facilitate correct COVEC-F
maintenance.
Advice

Procedures that must be performed to enable the best possible COVEC-F

maintenance.

Note

Information assisting in the best possible COVEC-F maintenance.

FOREWORD
This service manual describes the disassembly,
inspection, reassembly, and adjustment of
COVEC-F (Computed VE pump Control system
-Full).
Refer to the separate service manuals listed
below to facilitate COVEC-F maintenance.
This manual is intended for use by vehicle
maintenance technicians or persons with an
adequate knowledge of injection pumps.

The contents of this manual, including

illustrations, drawings and specifications were
the latest available at the time of printing.
The right is reserved to make changes in
specifications and procedures at any time
without notice.

Tokyo, Japan
Service Manual

Publication Number

COVEC-F Construction & Operation

EE14E-11080

Fuel Pump TEST STAND 7NP & 15NP Operation Manual

EC18E-11013

CONTENTS
1

SERVICE PRECAUTIONS

SPECIAL TOOLS

1. DISASSEMBLY, INSPECTION AND

REASSEMBLY TOOLS

2. SPECIAL TOOLS FOR ADJUSTMENT

3

DISASSEMBLY

1. PREPARATION

2. EXPLODED VIEW
3. DISASSEMBLY
4

INSPECTION

1. PREPARATION
2. INSPECTION

REASSEMBLY

ADJUSTMENT

1. FUEL PIPING

2. ADJUSTMENT CONDITIONS

15
15
16
25
25
26
35

15

49
49
51

3. MANUAL CONTROLLER FOR

ADJUSTMENT

51

4. INJECTION PUMP
ADJUSTMENT OUTLINE

5. INJECTION PUMP ADJUSTMENT

7

TIGHTENING TORQUES

PART NUMBER EXPLANATION

54
55
69
70

SERVICE PRECAUTIONS
(1) Handling
Never bump or drop the injection pump.

Injection pump

P-COVR-001

When carrying the injection pump, always

carry it by the pump body.

CAUTION

Wire harness

Never carry the injection pump by the GE

actuator or wire harnesses.
Carrying the pump by the harnesses may
result in personal injury or pump damage.

P-COVR-002

(2) Disassembly and reassembly

Only the mechanical components of the
injection pump body can be disassembled
and reassembled.
Advice
Do not disassemble the GE actuator unless
directed to do so.
The GE actuator consists of electrical
components. Do not damage these
components.

GE actuator

P-COVR-003

Wire harness

Harness connectors
P-COVR-004

-1-

When cleaning the injection pump, do not

clean the GE actuator wire harnesses or
harness connectors using light oil.
Clean them using only waste cloth.

SPECIAL TOOLS
1. DISASSEMBLY, INSPECTION AND REASSEMBLY TOOLS
[1] Tool use locations
11

16, 17
7

10
18

19
8

15

6
2
14
12, 13

P-COVR-005

-2-

SPECIAL TOOLS
[2] Tool application
The following special tools (in addition to general tools) are required for the disassembly and
reassembly of the VE injection pumps.
Key No.

Part No.

Part Name

Qty

Application

157944-8520 Universal vise

Used with brackets (Key no 2, 3 and 4)

157944-7920 Bracket

For fixing VE pump

157944-7200 Bracket

For fixing above bracket (key no 2)

010010-2200 Bolt

For fixing above bracket (key no 2)

157829-0420 Measuring device

For measuring 'KF' and 'K' dimensions

(used together with key no 14)

157914-2500 Socket wrench

For removing and installing distributor head plug

157913-7000 Socket wrench

For removing and installing regulating valve

157829-5420 Feed pump holder

For removing and installing feed pump assembly

157914-1100 Socket wrench

For removing and installing delivery valve holder

10

157922-0900 Oil seal guide

For protecting oil seal (shaft dia: 17)

11

157922-1100 Oil seal guide

For protecting oil seal (shaft dia: 20, for long shaft)

12

157925-2420 Extractor

For removing oil seal (shaft dia: 17)

13

157925-2720 Extractor

For removing oil seal (shaft dia: 20)

14

157954-3600 Dial gauge

For measuring 'KF' and 'K' dimensions

(used together with key no 5)

15

157844-1020 Holder

For measuring wear on plain bearing

16

105782-4200 Measuring device

Used together with key no 15 (shaft dia: 17)

17

105782-4130 Measuring device

Used together with key no 15 (shaft dia: 20)

18

157954-4100 Dial gauge

Used together with key no 15

19

157844-0900 Pin

Used together with key no 15 and 18

Note:
Key numbers 5 ~ 14 are included in the VE pump special tool kit (part no 105790-6040).

-3-

SPECIAL TOOLS

1.

157944-8520

Universal vise

2.

157944-7920

120
50

530

660

Bracket

98

145

102

15

45

90
180
84

3.

157944-7200 Bracket

4.

010010-2200

124

Bolt
M10X1.5

56

225

37

M10X1.5
4-M8X1.25
22
84
110

5.

157829-0420

Measuring device

6.

157914-2500

Socket wrench

SW17
16

60
25.1

16

12.7

6
30

35

-4-

SPECIAL TOOLS

7.

157913-7000

Socket wrench

8.

157829-5420

Feed pump holder

SW12

17

30

11.5

12.2

57 16.5
65.2

17.5
10.1

9.

157914-1100

165

Socket wrench

10. 157922-0900

Oil seal guide

12.7
77
17

38

20.5

M12X1.75

15

14

11. 157922-1100

Oil seal guide

12. 157925-2420

69

63

Extractor

18
8

50

20

21

3
15

19.5

12

M14X1.5

70
16.5

-5-

200

SPECIAL TOOLS

13. 157925-2720

69

Extractor

14. 157954-3600 Dial gauge

10

50

20

19.5

15

24

65

200

70
16.5

15. 157844-1020

Holder

16. 105782-4200

Measuring device

18

75

87
50

32

M12x1.75
20

142
17
4.5

17. 105782-4130

Measuring device

18. 157954-4100

Dial gauge
35

75

20

M14X1.5

66.5

-6-

SPECIAL TOOLS

19. 157844-0900

Pin

20

-7-

SPECIAL TOOLS
2. SPECIAL TOOLS FOR ADJUSTMENT
[1] Tool use locations
17, 18

16

14
18
8

13

10
12
11

7, 8
2

1, 2
15

9
4

P-COVR-006

-8-

SPECIAL TOOLS
[2] Tool application
Key No.

Part No.

Part Name

Qty

Application

105781-0361 Fixing stand

For pump drive side; Center height: 110 mm

105781-0610 Fixing stand

For pump drive side; Center height: 125 mm

105780-8190 Nozzle & nozzle holder

assembly

New injection system

( Nozzle holder part no :
Nozzle part no:

157805-7320 Injection pipe

Inside dia 2 outside dia6 - length 450 mm

157641-4720 Joint assembly

For fixing key no 3

157641-4020 Tube assembly

Used together with key no 5

157842-4620 Coupling

For pump drive side (shaft dia: 20)

157842-4420 Coupling

For pump drive side (shaft dia: 17)

105782-8260 Measuring device

For measuring timer stroke

(high pressure side)

10

105782-8160 Measuring device

For measuring pre-stroke

11

157954-4100 Dial gauge

Used together with key no 10

12

157829-0820 Adjusting device

For adjusting regulating valve pressure

13

157928-2920 Pliers

For disassembling regulating valve

14

157829-5220 Inserter

For reassembling regulating valve

15

157970-0500 Measuring cylinder

For measuring overflow

16

157845-6320 Piping assembly

For fuel piping

17

105784-1100 Accumulator assembly

For 5NP pump test stand

18

105784-1110 Accumulator assembly

For 10NP pump test stand

19

157845-6100 Bracket

For fine adjustment of GE actuator

20

407980-2270 Manual controller

21

See page 13

22

Commercially Digital voltmeter

available

105780-2150;
105780-0060)

Intermediate harness
1

Note:
Center height is the distance between the center of the pump test stand fly wheel and the driving
stand.

-9-

SPECIAL TOOLS

1.

105781-0361

Fixing stand

2.

105781-0610

Fixing stand

90

90
M8X1.25

M8X1.25

50

50

110

3.

125

105780-8190 Nozzle & nozzle

holder assembly
SW12
SW12

4.

157805-7320

Injection pipe

SW5

M14X1.5

M10X0.7
SW14

SW19
SW17
M12X1.5

SW14

SW24
M14X1.5

450

ZW14

5.

157641-4720

Joint assembly

6.

157641-4020

Tube assembly

SW30
M20X1.5
250

12

SW17
SW14
SW12

SW10

250
75

1105

- 10 -

SPECIAL TOOLS

7.

157842-4620

Coupling

8.

157842-4420

71

Coupling

71
20

17

10

9.

10

105782-8260
2-

Measuring device
6.4

10. 105782-8160

Measuring device
SW17

40

8
SW17

105780-2190
SW17
M8X1

133
148.5

11. 157954-4100

Dial gauge

12. 157829-0820

Adjusting device

35
SW17

M10X1
SW17

8
30

66.5

- 11 -

66

SPECIAL TOOLS

13. 157928-2920

Pliers

14. 157829-5220

Inserter
16
12

11.2

4.4
40

4.5

15. 157970-0500

Measuring cylinder

16. 157845-6320

Piping assembly

19. 157845-6100

Bracket

53

365

17. 105784-1100
18. 105784-1110

Accumulator
assembly

6.3
66

20

- 12 -

SPECIAL TOOLS

20. 407980-2270 Manual controller

COVEC MA

NUAL CONT

ROLLER

3456

P-COVR-007

21. Intermediate harness

No.

Part no

Manufacturer

Engine type

407980-2340

ISUZU

4JG2

407980-2310

NISSAN

CD20, TD27

- 13 -

Remarks

SPECIAL TOOLS

22. Digital voltmeter (Commercially available)

- 14 -

DISASSEMBLY
1. PREPARATION
Clean the outside of the injection pump
assembly and drain fuel oil from the pump.
Keep the work bench clean and tidy.
Before starting disassembly, record
performance data and the positions of
adjustable parts for later reference. This data
will facilitate the detection and diagnosis of
any malfunctions and defects.

During disassembly, put the disassembled

parts neatly and sequentially on the work
bench, labeling them if necessary to facilitate
later reassembly.
The plungers and delivery valves are
precision parts. Keep them in clean fuel oil.

2. EXPLODED VIEW

878S

P-COVR-008

- 15 -

DISASSEMBLY
3. DISASSEMBLY
[1] Injection pump installation
(1) Remove the overflow valve and drain the
fuel oil from the pump.
Note:
Inspect the plain bearing for wear (see page
26) before disassembly.

P-COVR-009

Universal vise

(2) Attach bracket A to the universal vise.

(3) Attach bracket B to bracket A.

Bolt (M10x1.5)
Bracket B

Bolts
(2; M8x1.25, L30)

Tool name

Part no

Universal vise

157944-8520

Bracket A

157944-7200

Bracket B

157944-7920

Bolt

010010-2200

Remarks

M101.5

Bracket A
P-COVR-010

Injection pump

Existing bolts
(2; M8x1.25, L30)

P-COVR-011

(5) Remove the existing bracket, and then

remove the harness connectors from the
bracket.

Harness connectors

Existing bracket

Socket head bolts

(2)

(4) Attach the injection pump to bracket B.

Bracket B

Bolt

P-COVR-012

- 16 -

DISASSEMBLY
GE actuator

[2] GE actuator removal

GE actuator

(1) Scratch two marks on the GE actuator and

the pump housing at two locations as shown
at left.
Note:
The marks are made to facilitate later
adjustment.

Aligning marks

P-COVR-014

(2) Remove the GE actuator fixing screws and

spring washers.

GE actuator

Screws (3)

P-COVR-015

(3) Remove the GE actuator.

Advice
Do not damage the ball pin during removal.

GE actuator

Ball pin

P-COVR-016

[3] Np sensor removal

Remove the Np sensor.

Np sensor

P-COVR-017

- 17 -

DISASSEMBLY
[4] Regulating valve removal
Socket wrench

Remove the regulating valve using the socket

wrench.

Regulating valve

Tool name
Socket wrench

Part no

Remarks

157913-7000

P-COVR-018

[5] Magnet valve removal

Magnet valve

Magnet valve

Remove the magnet valve.

Note:
Do not lose the armature or spring.

O-ring
Spring
Armature

P-COVR-019

[6] TCV (Timing control valve) removal

TCV

(1) Remove the TCV fixing bolts.

Socket head bolts (2)

P-COVR-035

(2) Remove the TCV by levering it up evenly

using screwdrivers on the left and right.
Advice
Do not scratch the pump housing with the
screwdrivers.

TCV

P-COVR-036

- 18 -

DISASSEMBLY
[7] Delivery valve holder and plug
removal

Delivery valve holder

(1) Remove the delivery valve holders using the

socket wrench.
Tool name

Part no

Remarks

Socket wrench 157914-1100

Socket wrench

Distributor
head

P-COVR-020

Advice
Line up the removed delivery valve holders
to align with their respective distributor head
stampings (A, B, C and D).
(2) Remove the delivery valve springs, delivery
valve assemblies and gaskets.
Advice
Line up the removed delivery valve springs
and delivery valve assemblies to align with
their respective distributor head stampings
(A, B, C and D).

Delivery valve spring

Delivery valve assembly

Gasket

P-COVR-021

(3) Remove the plug.

Tool name
Part no

Socket wrench
Plug

Remarks

Socket wrench 157914-2500

P-COVR-022

[8] Distributor head removal

Distributor head

(1) Remove the distributor head by loosening

the distributor head fixing screws gradually
and evenly so that the distributor head rises
evenly.
Advice
If the distributor head does not rise, tap the
sides lightly with a plastic hammer.

Screws (4)

P-COVR-023

- 19 -

DISASSEMBLY
(2) Insert the tip of a finger between the bottom
of the plunger and the cam disk, then
remove the distributor head, plunger,
plunger spring and control sleeve together.
Advice
When lifting the distributor head, hold the
plunger with your finger so that it does not
fall out. After lifting the distributor head,
hold the plunger with the finger holding the
distributor head.

Distributor head

Plunger

Cam disk

P-COVR-024

[9] Cam disk and roller assembly

removal

Shim

(1) Remove the cam disk and shim.

Advice
The shim is positioned on top of the center
of the cam disk. Do not lose the shim.

Cam disk

P-COVR-025

Spring

(2) Remove the disk and spring.

Disk

P-COVR-026

(3) Remove the timer cover, O-ring, timer spring

and shims.

Shim
Timer spring
Shim
O-ring

Timer cover
Bolts (2)
P-COVR-027

- 20 -

DISASSEMBLY
[10] T P S ( t i m e r p i s t o n s e n s o r )
removal

Socket head bolts (2)

When installed
(1) Remove the bobbin fixing bolts.

Bobbin
P-COVR-028

Timer spring

(2) Remove the TPS standard point shim, core

rod, timer spring and timer stroke adjusting
shim.
Advice
Label the TPS standard point shim and the
timer stroke adjusting shim to avoid mixing
them up at reassembly.

TPS standard point shim

(Thickness: 1.2 mm)

Core rod

Timer stroke adjusting

shim

P-COVR-029

[11] Roller holder assembly removal

(1) Remove the clip.

Clip

P-COVR-030

(2) Remove the pin.

Pin

P-COVR-031

- 21 -

DISASSEMBLY
(3) Move the roller holder pin to the center of
the roller holder assembly to separate it from
the timer piston.

Roller holder pin

P-COVR-032

(4) Remove the roller holder assembly.

Advice
Do not change the assembly position of each
roller, bushing or roller pin.

Roller holder assembly

P-COVR-033

[12] Timer removal

Remove the timer piston and slider. Catch the
slider to prevent it from dropping.
Timer piston

Slider

P-COVR-034

[13] Drive shaft removal

Drive shaft

(1) Align with and then attach the oil seal guide
to the drive shaft.
Tool name
Part no
Remarks
Oil seal guide 157922-0900
17
Oil seal guide 157922-1100

Oil seal guide

P-COVR-037

- 22 -

20

DISASSEMBLY
(2) Remove the drive shaft.
Advice
Do not damage the drive shaft's speed pick
up projections.
Projection

Drive shaft

P-COVR-038

[14] Feed pump removal

(1) Fully loosen the feed pump fixing screws.
Advice
Do not remove the screws at this time.

Screws (2)

P-COVR-039

(2) Insert the feed pump holder into the pump

housing. At this time, align the holder's two
holes with the feed pump fixing screws.

Feed pump holder

Tool name

Part no

Feed pump
holder

157829-5420

Remarks

Screw

P-COVR-040

(3) Remove the pump housing from the bracket.

Pump housing

P-COVR-041

- 23 -

DISASSEMBLY
(4) Hold the feed pump holder and turn the
pump housing upside down.
(5) Remove the feed pump holder, with the feed
pump on top, straight down out of the pump
housing.
Advice
The feed pump must be removed as an
assembly.

Feed pump holder

Feed pump

P-COVR-042

- 24 -

INSPECTION
1. PREPARATION
Following disassembly, inspect each part for wear and damage. Repair or replace any worn or
damaged parts.
Always replace all gaskets, O-rings and rubber dampers with new parts.

10

11

1011
8
7

12

6
5
2
1
3

13
15

14

P-COVR-043

Repair kit (part number: 146600-4620)

Key no Part name

Part no

Qty

Remarks

O-ring

146600-3000

For timer

2
3

O-ring
Gasket

146600-0000
146433-0100

1
6

Head housing
Delivery valve

4
5

Seal ring
Gasket

148600-1300
139508-0200

1
1

GE housing
For air bleeder bolt

6
7

O-ring
O-ring

146600-0500
146600-0600

1
1

Head plug
Regulating valve

8
9

O-ring
O-ring

046600-0700
146600-1700

1
1

Regulating valve
Magnet valve

10
11

Gasket
Gasket

139512-0500
139512-0200

6
6

In and out (t=1.6)

In and out (t=1.0)

12
13

O-ring
Cap

479773-6500
029921-2010

1
6

Pickup
Delivery valve holder

14
15

O-ring
O-ring

161440-3800
161440-3700

1
1

TCV (small)
TCV (large)

- 25 -

INSPECTION
2. INSPECTION
[1] Pump housing
(1) Replace the pump housing if it has been
worn by the feed pump rotor and plate or
the timing control valve.

P-COVR-044

(2) Replace the pump housing if the timer piston

sliding surface is scratched or worn.

P-COVR-045

[2] Plain bearing wear inspection

Measure wear of the plain bearing pressfitted
to the pump housing as described below.
Replace the pump housing if wear exceeds the
limit.
Wear limit: not exceeding 0.25 mm
(1) Attach the pin to the dial gauge.

Dial gauge

Pin

Tool name

P-COVR-046

18

Dial gauge

157954-4100

Pin

157844-0900

Remarks

Advice
Match the location of holder clamp use to
drive shaft diameter and length (see below).

Holder

Tool name

32

Holder

C
Holder clamp

Part no

4.5

A
P-COVR-047

- 26 -

Part no

Shaft dia

157844-1020 17

Clamp

20 (long shaft)

20 (extra-long shaft)

INSPECTION
Advice
Measure plain bearing wear on the
injection pump assembly.
Plain bearing wear is measured in the
direction of pump drive belt (or gear)
force.
(2) Set the holder clamps where wear is to be
measured and attach the holder to the pump
housing flange.

Holder

Holder clamps
P-COVR-048

(3) Attach the dial gauge to the holder clamp

where wear is to be measured.
(4) Screw the measuring device on to the drive
shaft.
Tool name
Part no
Remarks

Measuring device

Dial gauge

157954-4100

Measuring device 105782-4200 For17

Measuring device 105782-4130 For20
Dial gauge

P-COVR-049

(5) Zero the dial gauge.

(6) Move the drive shaft towards the dial gauge
using the measuring device, and measure
wear.

Drive shaft

Measuring device

P-COVR-050

[3] Oil seal

Oil seal

Replace the oil seal using the extractor if the oil

seal lip is damaged or worn.
Advice
In principle, oil seals are replaced when
overhauling the pump.
Tool name
Part no
Remarks
Extractor 157925-2420 Shaft dia: 17
Extractor 157925-2720 Shaft dia:20
P-COVR-051

- 27 -

INSPECTION
[4] Oil seal removal
(1) Insert the collet into the oil seal.
Tool name
Collar

Part no

Remarks

Collet

157925-2400 For Shaft dia: 17

Collet

157925-2700 For Shaft dia: 20

Note:
The collet as well as the bar and pushrod (see
figure below) are part of the extractor.

Oil seal
P-COVR-052

Press

Pushrod

(2) Insert the bar into the collet from the pump
housing side.
(3) Position the pushrod against the bar, and
then remove the oil seal using a press.

Bar

Tool name

Oil seal
Collar

Part no

Remarks

Bar

157925-2500 For Shaft dia: 17

Bar

157925-2800 For Shaft dia: 20

Pushrod 157926-1000

P-COVR-053

[5] Oil seal installation

Oil seal
Press

Press the new oil seal down using a press to

press fit it to the pump housing end face.

P-COVR-054

[6] Feed pump assembly

Cover

(1) Replace the feed pump assembly if the

inside of the liner has been peeled or
gnawed by the plate.
(2) Replace the feed pump assembly if there
are impact marks on the inside edges of the
liner.
(3) Replace the feed pump assembly if the rotor
or plate are rusted or gnawed.

Liner
Rotor

Plate

P-COVR-055

- 28 -

INSPECTION
[7] Drive shaft assembly
Projection
Washer

Drive shaft assembly

P-COVR-056

Disk
Drive shaft

(1) Replace the drive shaft assembly if the drive

key or the feed pump drive key grooves are
damaged.
(2) Replace the drive shaft assembly if the taper
is damaged or worn.
(3) Replace the drive shaft assembly if the
thread is damaged.
(4) Replace the drive shaft assembly if the shaft
or oil seal contact area is worn.
(5) Replace the drive shaft assembly if the
washer's sliding surface is peeling, gnawed
or scorched.
(6) Replace the drive shaft assembly if there
are impact marks on or damage to the
projections.
(7) Replace the drive shaft assembly if there is
play between the drive shaft teeth and the
disk.

P-COVR-057

[8] Roller holder assembly

(1) Replace the roller holder assembly or install
a new roller kit if any of the parts' sliding
surfaces are peeled, gnawed or scorched.

Roller holder assembly

P-COVR-058

Dial gauge

(2) Measure the height (h) of each roller using

a dial gauge. Replace the roller holder
assembly or install a new roller kit if the
differences between the heights exceed the
specification.
Specified difference: not exceeding
0.02mm

Roller

h
Rollers (4)

Roller holder assembly

P-COVR-059

- 29 -

INSPECTION
[9] Cam disk
A

Cam disk tooth

(1) Replace the cam disk and disk if there is

play between the cam disk teeth and the
disk.
Note:
Replacement is unnecessary if contact wear to
the flat face (A) does not affect performance.

Disk

P-COVR-060

(2) Replace the cam disk if the cam profile is

peeling or scorched.

Cam disk

P-COVR-061

Clip

[10] Timer

Slider

(1) Replace the piston if the outside surface of

the piston is worn.
(2) Replace the roller holder pin if it is worn.
(3) Replace the slider if it is worn.
Advice
Always replace the clip.

Piston

Roller holder pin

P-COVR-062

[11] Distributor head assembly

Distributor head

(1) Wash the distributor head assembly in clean

light oil.
Confirm that the control sleeve and plunger
stroke easily and slide smoothly.
(2) Replace the distributor head assembly if the
control sleeve and plunger do not move
smoothly.

Control sleeve

Plunger

P-COVR-063

- 30 -

INSPECTION
(3) Check the plunger's sliding surface (suction
slit, cutoff port). Replace the distributor head
assembly if it is worn or damaged.

Plunger

P-COVR-064

(4) Replace the distributor head assembly if

there is any play between the cam disk
knock pin and the plunger.

Plunger

Knock pin

P-COVR-065

[12]Delivery valve and delivery valve

holder
(1) Replace the delivery valve assembly if the
delivery valve piston or seat is damaged or
marked.

Delivery valve

P-COVR-066

(2) Replace the delivery valve holder if the seat

is worn.

Delivery valve holder

P-COVR-067

- 31 -

INSPECTION
[13]Plug, plunger spring and spring
seat
(1) Replace both plunger springs if either one
of the springs is rusted or damaged.
Advice
Always replace the plug with a new one.

Plug

Plunger springs

P-COVR-068

(2) Replace the spring seat and shim if they

are peeling or gnawed.

Spring seat

Shim

Spring seat
P-COVR-069

[14] Regulating valve

Regulating valve

Replace the regulating valve assembly if the

piston in the regulating valve sticks.
Advice
Always replace the O-rings with new ones.
Do not disassemble the regulating valve
unless faulty.

O-rings

P-COVR-070

[15] Magnet valve

Magnet valve

(1) Replace the magnet valve assembly if the

armature is cracked or scorched.
(2) Replace the magnet valve assembly if the
spring is damaged or rusted.
Advice
Always replace O-rings with new ones.
(3) Check magnet valve resistance and replace
the assembly if resistance is not as
specified.

O-ring

Spring
Armature
P-COVR-071

- 32 -

Resistance ()
Temperature (C)
8+1.2 (reference value)
23

INSPECTION
[16] GE actuator

Ball pin

(1) Replace the GE actuator if the ball pin is

worn.

GE actuator
P-COVR-072

(2) Insert the GE actuator's ball pin into the

control sleeve hole and check that there is
no play.
(3) If there is any play between the ball pin and
the control sleeve, replace the GE actuator
or distributor head assembly, or both.

GE actuator

Control sleeve

P-COVR-073

GE actuator terminals (reference)

7

Terminal
no
1
2

12
11

3
10

4
5
6
7
8
9
10
11
12

1
5

6
P-COVR-074

12
7
11
10

Name

Remarks

FCV
Q (-)

Magnet valve
Injection quantity (-)
compensation resistance
Q (+)
Injection quantity (+)
compensation resistance
OSC (+) CPS Oscillate (+)
TCV (+) Timing control valve (+)
GE (+) GE (+)
TF (+)
Fuel temperature (+)
OSC
CPS MDL
TCV (-) Timing control valve (-)
GE (-)
GE (-)
TF (-)
Fuel temperature (-)
OSC (-) CPS Oscillate (-)

(4) Measure the resistances between each of

the terminals.
Reference values
Terminal No.
4-8
4-12
8-12
6-10
7-11

P-COVR-075

- 33 -

Resistance
5.8
11.6
5.8
0.6
20.1 k

Temperature (C)
23
23
23
23
25

INSPECTION
[17] TCV (Timing control valve)
TCV

(1) Replace the TCV if it is scratched or worn.

(2) Check the filter for dirt. If the filter is dirty,
clean it using compressed air.

Filter
P-COVR-076

(3) Measure TCV resistance.

Reference value
Resistance ()
Temperature (C)
111.1
20

P-COVR-077

Timer spring

[18] TPS (Timer piston sensor)

TPS

If installed
(1) Replace the TPS if the inside of the TPS,
the core rod or the timer spring is worn.
(2) Measure TPS resistance.
Reference values
Terminals Resistance () Temperature (C)

Red 1
Black 2

Yellow 3

Core rod

3 Green

1-3

822

25

2-3

822

25

P-COVR-078

2 Black

[19] Np sensor

Np sensor

Measure Np sensor resistance.

Reference values
Terminals Resistance () Temperature (C)
1-2

1 Yellow

P-COVR-079

- 34 -

1.620.16

25

REASSEMBLY

Blade

VE injection pump reassembly is basically the

reverse of the disassembly procedure. The
following describes the basic reassembly
procedure. Always replace gaskets and O-rings
with new ones.

Liner

[1] Feed pump assembly

Rotor
P-COVR-080

Clockwise rotation

Counterclockwise rotation

Fuel discharge hole

Reference hole

Reference hole

P-COVR-081

Fuel discharge hole

Liner
Reference hole

b
a<b

Feed pump holder

P-COVR-082

Feed pump assembly

Screws (2)

Advice
Confirm that the blades' grooves face the
inside.
Blade and rotor orientation cannot be
changed.
Advice
The feed pump's standard installation
position depends on the direction of
injection pump rotation. Fuel will not be
discharged if the installation position is
incorrect.
Clockwise rotation: The reference hole
is on the right hand side when the
feed pump is viewed from the
drive side.
Counterclockwise rotation: The reference
hole is on the left hand side when
the feed pump is viewed from the
drive side.
Note:
1. The second figure from the top is a view
from the distributor head side.
2. The mounting holes are two diametrically
opposed holes. The reference hole is the
mounting hole positioned furthest from the
inside of the liner. The liners are marked R
(right) on one side. For clockwise rotation,
the R can be seen from the distributor head
side. For counterclockwise rotation, the R
cannot be seen.
(1) Place the feed pump assembly, together
with the cover and screws, on the feed pump
holder. The screw heads are positioned in
the feed pump holder holes (2).
Tool name
Part no
Remarks
Feed pump holder 157829-5420

Cover

P-COVR-083

- 35 -

REASSEMBLY
(2) Position the cover's notch at the Np sensor's
threaded hole and insert the feed pump
assembly into the pump housing.

Threaded Np sensor hole

Notch

Feed pump assembly

P-COVR-084

GE actuator side

(3) Before tightening the feed pump cover,

ensure that all holes align with the liner
holes, and that the fuel discharge hole faces
up (towards the GE actuator).

Fuel discharge hole

Feed pump cover

P-COVR-085

(4) Attach the pump housing to bracket B.

Pump housing

Bracket B

P-COVR-086

Screws (2)

(5) Tighten the feed pump cover screws evenly.

Tightening torque:
2.0 ~ 4.0 N.m
{0.2 ~ 0.4 kgf.m}
Advice
Move the rotor up and down and left and
right with your finger and check that it moves
smoothly. If it does not move smoothly,
loosen the feed pump cover and then
retighten it to the specified torque.

Rotor

P-COVR-087

- 36 -

REASSEMBLY
[2] Driveshaft
Oil seal guide

(1) Screw the appropriate oil seal guide onto

the driveshaft.
Tool name
Part no
Shaft dia.

Key

17

Oil seal guide

157922-0900

Oil seal guide

157922-1100 20 (long)

(2) Install the washer and feed pump drive key

on the driveshaft.

Washer
Drive shaft
P-COVR-088

(3) Align the driveshaft key with the feed pump

rotor's key groove, and then install the drive
shaft assembly.
Advice
Do not scratch the feed pump cover
groove when installing the driveshaft.
After installing the driveshaft, check that
it rotates smoothly.

Feed pump cover

Key

Drive shaft assembly

P-COVR-089

[3] Np sensor
(1) Screw the Np sensor into the pump housing.
Tightening torque:
20.0 ~ 25.0 N.m
{2.0 ~ 2.5 kgf.m}
Approx. 1 mm

Np sensor

Projection
P-COVR-090

Roller pin

Roller

(2) Insert a thickness gauge from the GE

actuator installation side and check that the
distance between the projections and the
tip of the Np sensor is approximately 1 mm.
(As the gap cannot be adjusted, the Np
sensor must be tightened to the specified
torque.)

[4] Roller holder assembly

Washer

(1) Assemble the rollers, bushings, roller pins

and washers in the roller holder.
Advice
The convex side of the washer faces the
outside.
The end of the roller with the larger
chamfer faces the outside.

Bushing

Roller holder assembly

Chamfer
P-COVR-093

- 37 -

REASSEMBLY

Hole

(2) Install the roller holder pin in the roller holder.

Advice
The end of the roller holder pin with the hole
is positioned in the center of the roller
holder. The hole faces up.

Roller holder pin

P-COVR-094

(3) Position the roller holder pin towards the

timer and then install the roller holder
assembly in the pump housing.

Roller holder assembly

Timer side

Roller holder pin

P-COVR-095

[5] Timer

Slider

(1) Coat the slider thinly with grease and install

the slider and shim in the timer piston. At
this time, align the slider hole with the timer
piston hole.

Hole

Shim

Hole
Timer piston

P-COVR-096

Note:
When viewed from the distributor head side,
the side of the timer with the hole is the low
pressure side.
The timer spring is installed at the low
pressure side.

Hole (low pressure side)

Viewed from
distributor head side

P-COVR-097

- 38 -

REASSEMBLY
(2) Assemble the timer piston and slider in the
pump housing.
Advice
Install the slider with the hole facing the
roller holder pin.

Timer piston

Slider hole
P-COVR-098

(3) Insert the roller holder pin into the slider. At

this time, position the pin hole facing up.

Roller holder pin

Hole
P-COVR-099

(4) Insert the pin into the roller holder pin.

Pin

Roller holder pin

P-COVR-100

(5) Attach the clip securely to the roller holder

pin.
Advice
Confirm that the timer piston slides
smoothly.

Clip

Timer piston
P-COVR-101

- 39 -

REASSEMBLY
(6) Install the cover and O-ring on the high
pressure side.
(7) Install the shim, timer spring, shim, cover
and O-ring on the low pressure side.
Tightening torque:
7.0 ~ 10.0 N.m
{0.7~ 1.0 kgf.m}

Bolts (2)
Cover
O-ring

Shim
Timer spring
Shim
O-ring

Cover
Bolts (2)
Low pressure side

P-COVR-102

[6] TPS (Timer piston sensor)

O-ring
Bobbin

Socket head
bolts (2)
Adjusting shim

Plunger

Standard point
shim (thickness:
1.2 mm) P-COVR-103

Core rod
Timer spring

If installed
(1) Install the TPS standard point shim, core
rod, timer spring and timer stroke adjusting
shim in the pump housing.
(2) Install the bobbin in the pump housing.
Tightening torque:
7.0 ~ 10.0 N.m
{0.7~ 1.0 kgf.m}
Advice
Do not mistake the TPS standard point shim
and the timer stroke adjusting shim.

[7] Measuring the K dimension

Note:
The K dimension is a plunger assembly
dimension, and is the distance from the end face
of the distributor barrel to the end face of the
plunger when the plunger is in the bottom dead
center position.

Distributor barrel

P-COVR-104

(1) Assemble the disk to the driveshaft teeth

as shown at left.
Advice
Do not assemble the spring to the disk at
this time.

Distributor head side

Disk

Drive shaft side

P-COVR-105

- 40 -

REASSEMBLY
(2) Position the driveshaft's key groove towards
the GE actuator's installation position.

Key groove

P-COVR-106

(3) Align the cam disk's knock pin with the

driveshaft's key groove and then assemble
the cam disk to the roller holder.

Cam disk

Knock pin

Key groove

Shim

P-COVR-107

(4) Position the shim in the center of the cam

disk.

Cam disk

P-COVR-108

Knock pin

(5) Remove the plunger spring, spring seat,

guide pin, shim, washer and distributor head
O-ring from the distributor head assembly.
(Refer to center figures on the next page.)
(6) Assemble the plunger and distributor head
together so that the groove at the bottom of
the plunger fits the knock pin.
Advice
Rotate the driveshaft and confirm that the
plunger rotates.

Distributor head

Plunger

Cam disk

P-COVR-109

- 41 -

REASSEMBLY
(7) Rotate the driveshaft to position the plunger
in the bottom dead center position.
(8) Attach the measuring device to the dial
gauge, press it against a surface plate and
zero the dial gauge.

Dial gauge

Tool name
Dial gauge

Part no

Remarks

157954-3600

Measuring device 157829-0420

Measuring device

P-COVR-110

(9) Insert the dial gauge into the distributor head

and measure the K dimension (refer to the
data sheet).
(10) If the K dimension is not as specified, adjust
it to the specification by replacing the shim
[see (4) above and table below].

Dial gauge

Part no

P-COVR-111

Cam disk

Thickness (mm)

Remarks

146420-0000

146420-5000

1.09

2.90

51 types; varying
in 0.2 mm increments

146420-5100

146420-5800

1.74

1.88

8 types; varying
in 0.2 mm increments

(11) After measuring the K dimension, remove

the cam disk and assemble the spring to
the disk.
(12) Reinstall the cam disk.
Advice
Confirm that the shim is positioned in the
top center of the cam disk.

Shim
Spring

P-COVR-112

[8] Measuring the KF dimension

KF

Note:
The KF dimension is related to the set length of
the plunger spring, and is the distance between
the end face of the distributor barrel and the
end face of the plunger.
Plunger

Distributor barrel
P-COVR-113

- 42 -

REASSEMBLY
Spring seat

Plunger

Shim

Washer

(1) Assemble the plunger, spring seat, and the

parts shown at left in the distributor head.
Advice
The chamfered end of the control sleeve
faces the distributor head.

Guide pin

Spring seat
P l u n g e r
spring

Shim
Control sleeve

Distributor head
P-COVR-114

(2) Attach the measuring device to the dial

gauge, press it against a surface plate and
zero the dial gauge.
Tool name
Part no
Remarks

Dial gauge

Dial gauge

157954-3600

Measuring device 157829-0420

Measuring device
P-COVR-115

(3) Insert the dial gauge into the distributor head

and measure the KF dimension (refer to the
data sheet).

Dial gauge

Distributor head

P-COVR-116

(4) If the KF dimension is not as specified, adjust

it to specification by replacing the left and right
shims (as a set).

Shim

Shim

Distributor head
P-COVR-117

- 43 -

Shim part no

Thickness (mm)

Shim part no Thickness (mm)

146603-0000

0.50

146690-1400

0.90

146603-0100

0.80

146690-1500

1.10

146603-0200

1.00

146690-1600

1.30

146603-0300

1.20

146690-1700

1.40

146603-0400

1.50

146690-1800

1.60

146603-0500

1.80

146690-1900

1.70

146603-0600

2.00

REASSEMBLY
[9] Distributor head assembly
(1) Coat the shim thinly with grease and
assemble it in the recess at the bottom of
the plunger.
(2) Install a new O-ring on the distributor head.

Shim
Plunger

O-ring

Distributor head

P-COVR-118

Knock pin
Distributor head
assembly

(3) Assemble the distributor head assembly to

the pump housing so that the groove at the
bottom of the plunger fits the cam disk knock
pin.

P-COVR-119

(4) Confirm that the groove at the bottom of the

plunger fits the cam disk knock pin.
(5) Confirm that the distributor head can be
pressed down by hand to where the O-ring
is installed.
Advice
Press the distributor head down slowly to
prevent O-ring damage.

Distributor head
O-ring

P-COVR-120

[10] Securing the distributor head

Distributor head

(1) Fix the distributor head to the pump housing.

Tightening torque:
10.0 ~ 14.0 N.m
{1.0 ~ 1.4 kgf.m}

Screws (4)

P-COVR-121

- 44 -

REASSEMBLY
(2) Install a new plug with a new O-ring in the
distributor head.
Tightening torque:
59.0 ~ 78.0 N.m
{6.0 ~ 8.0 kgf.m}

Socket wrench
Plug

Tool name

Part no

Remarks

Socket wrench 157914-2500

P-COVR-122

[11] Delivery valve holders

Gasket

Delivery
assembly

Distributor head

valve

Delivery valve holder

(1) I n s t a l l t h e g a s k e t s , d e l i v e r y v a l v e
assemblies and delivery valve springs in the
distributor head, then install the delivery
valve holders.
Advice
Reinstall each delivery valve holder and
related parts in their original positions in the
distributor head (ie, to align with the marks
A, B, C and D).

Delivery valve spring

P-COVR-123

Delivery valve holder

(2) Tighten the delivery valve holders as

described below to the specified torque.
Tightening torque:
44.0 ~ 54.0 N.m
{4.5 ~ 5.5 kgf.m}
Note:
To tighten the delivery valve holders, tighten
them to the specified torque, loosen them, and
then tighten them again to the specified torque.

Socket wrench

Tool name
Part no
Socket wrench 157914-1100

P-COVR-124

[12] TCV (Timing control valve)

Light oil

(1) Coat the O-rings with light oil.

O-ring
TCV
O-ring

Remarks

P-COVR-091

- 45 -

REASSEMBLY
(2) Press the TCV into the pump housing by
hand as far as possible and then fix it using
the bolts.
Tightening torque:
7.0 ~ 10.0 N.m
{0.7 ~ 1.0 kgf.m}

Socket head bolts (2)

TCV
P-COVR-092

[13] Magnet valve assembly

Magnet valve assembly

Screw the magnet valve assembly into the

distributor head and tighten it to the specified
torque using a torque wrench.
Tightening torque:
20.0 ~ 25.0 N.m
{2.0 ~ 2.5 kgf.m}

Torque wrench
P-COVR-125

[14] Regulating valve

Socket wrench

Torque wrench

Regulating valve

P-COVR-126

Screw the regulating valve into the pump

housing and tighten it to the specified torque
using a torque wrench.
Tightening torque:
10.0 ~ 13.0 N.m
{1.0 ~ 1.3 kgf.m}
Tool name
Part no
Remarks
Socket wrench 157913-7000
Advice
Regulating valve performance is determined
when adjusting the pump.

[15] GE actuator

Seal ring

(1) Install a new seal ring on the GE actuator.

GE actuator
P-COVR-127

- 46 -

REASSEMBLY
(2) Position the control sleeve in the center with
the hole facing up. (This facilitates GE
actuator installation.)

Control sleeve

Hole
P-COVR-128

Ball pin

(3) Insert the GE actuator's ball pin into the

control sleeve hole.

GE actuator

P-COVR-129

(4) Confirm that the GE actuator moves

smoothly left and right, backwards and
forwards, as shown at left.
Advice
Do not force the GE actuator to move.
Forcing it may damage the seal ring.
The GE actuator will not move if its ball pin
is not inserted into the control sleeve hole.
If it will not move, disassemble the GE
actuator and then reassemble it.

GE actuator

P-COVR-130

Aligning mark

(5) Align the two GE actuator-pump housing

scratch marks made at disassembly.

GE actuator
Aligning mark

P-COVR-131

- 47 -

REASSEMBLY
Screws (3)

(6) Fix the GE actuator to the pump housing.

Tightening torque:
7.0 ~ 9.0 N.m
{0.7 ~ 0.9 kgf.m}

GE actuator

P-COVR-133

[16] External parts

(1) Reinstall the harness connectors to the
bracket in their original positions.
(2) Install the harness connector bracket on the
injection pump.

Bracket

Harness connectors
P-COVR-134

Advice
Confirm that all injection pump parts have
been reinstalled.

P-COVR-135

- 48 -

ADJUSTMENT
1. FUEL PIPING
[1] 5NP and 10NP pump test stands
Key
no

Part no

Part name

5NP

Qty

10NP

Remarks

Pump test stand

105760-0010 105760-0500

50Hz

Pump test stand

105760-0020 105760-0510

60Hz

Eye bolt

029731-4080 029731-4080

Accessory for 5NP and 10NP pump test stands

Gasket

026514-2040 026514-2040

Same as above

Eye

029711-4190 029711-4190

Same as above

Accumulator assembly

157845-2320 157845-2420

Part of accumulator kit part nos: 105784-1100, -1110

Hose

157984-7400 157984-7400

Same as above

Eye bolt

027412-2440 027412-2440

Same as above

Gasket

026512-1640 026512-1640

Same as above

Eye

029711-2240 029711-2240

Same as above

Gasket

026512-1640 026512-1640

Same as above

10

Eye

029711-2160 029711-2160

Same as above

11

Bolt

157975-8800 157975-8800

Same as above

12

Eye

029711-2180 029711-2180

Same as above

13

Hose

157984-8100 157984-8100

Same as above

14

Hose

157986-0500 157986-0500

Part of accumulator kit part nos: 105784-1100, -1110

P1

Pressure gauge

157955-4000 157955-4000

Key no 4: Part of 157845-2320, -2420

P2

Pressure gauge

157955-4000 157955-4000

Same as above

P3

Pressure gauge

157955-3900 157955-3900

Key no 4: Part of 157845-2320, -2420

Piping outline

Note:
P1: 2 kgf/cm2

1, 2, 3

P2: 2 kgf/cm2
P3: 15 kgf/cm2
P1

14

P2

P3

9, 10

Overflow valve
(Use COVEC-F part)
13

12 11

6, 7, 8

Nozzle holder

P-COVR-136

- 49 -

ADJUSTMENT
[2] 7NP and 15NP pump test stands
Key
no

Part no

Part name

7NP

Qty

15NP

Remarks

Pump test stand

105761-0062 105762-0092

50Hz

Pump test stand

105761-0072 105762-0132

60Hz

Hose

157984-8400 157984-8400

For adjusting pump chamber pressure

Hose

157984-7100 157984-7100

For fuel inlet

Eye

029711-2240 029711-2240

For fuel inlet

Gasket

026512-1640 026512-1640

For fuel inlet

Eye bolt

029731-2010 029731-2010

For fuel inlet

Gasket

026512-1640 026512-1640

For overflow

Eye

029711-2160 029711-2160

For overflow

Bolt

157975-8800 157975-8800

For overflow

Eye

029711-2180 029711-2180

For overflow

10

Hose

157986-2000 157986-2000

For fuel return

11

Eye

029711-4420 029711-4420

For fuel return

Note:
Key nos 1 ~ 5 are pump test stand parts.
Key nos 6 ~ 11 are piping kit (157845-6320) parts.

Piping outline

1
Overflow valve
(Use COVEC-F) part
8

2
3

Nozzle holder

10

11

P-COVR-137

- 50 -

ADJUSTMENT
2. ADJUSTMENT CONDITIONS
New injection system piping (Kit part no: 105765-1350)
Tube assembly (part no: 157641-4020)
Nozzle and nozzle holder assembly (Part no: 105780-8190)

VE pump

Injection pipes (Part no: 157805-7320)

Joint assembly (Part no: 157641-4720)

P-COVR-138

3. MANUAL CONTROLLER FOR ADJUSTMENT

[1] Wiring
Injection pump

To AC 100 V source

Intermediate harness
FCV
GND

Earth to injection pump or pump

test stand

FG
Manual controller

Earth to pump test stand

P-COVR-139

- 51 -

ADJUSTMENT
[2] Manual controller operation outline
(1) Front panel
9

Key
no
1
Power switch

10

13

14

11

12

15

Name

P-COVR-140

Use and purpose

Manual controller's power switch. Turn ON during use.

FCV (magnet valve) ON/OFF switch

Turns the FCV (magnet valve) on and off. Usually turned on.

Cylinder set switch

Set to number of engine cylinders. [If not set to number

of engine cylinders, pump speed display (Key no 13)
differs from actual speed.]

Control sleeve position target voltage

setting dial

Sets control sleeve to any desired position.

Target timer position setting dial

Sets timer to any desired position.

TCV duty ratio dial

Sets TCV duty ratio to any desired setting.

TCV drive frequency dial

Sets TCV drive frequency to any desired setting.

Timing control closed loop/open loop

Sets timing control at open loop or closed loop.

changeover switch
9

Actual control sleeve position voltage

Displays actual control sleeve position voltage.

10

TPS output voltage

Displays TPS output voltage.

11

TCV duty ratio display

Displays TCV duty ratio.

12

TCV drive frequency display

Displays TCV drive frequency.

13

Pump speed display

Displays pump speed.

14

Fuel temperature display

Displays pump chamber fuel temperature.

15

Control sleeve position target voltage

display

Displays control sleeve position target voltage.

- 52 -

ADJUSTMENT
(2) Rear panel
6

5
P-COVR-141

Key
no
1

Name

Use and purpose

Pump side wire harness terminal

For connecting wire harness between each injection

FCV (magnet valve) ground terminal

pump harness connector and manual controller.

Connect to injection pump body.

3
4

Frame ground terminal

Fuse

Connect to any earth.

3A

5
6

AC100V power terminal

NLS (needle lift sensor) input terminal

Connect to AC100V
For connecting harness of needle lift sensor equipped

NLS (needle lift sensor) output terminal

nozzle holder via intermediate harness.

For connecting oscilloscope harness (oscilloscope

is prepared separately). Enables viewing of needle lift

sensor output wave form.

(3) Manual controller precautions

Observe the following when connecting the
manual controller's wire harness to the injection
pump.
Turn the controller's power switch OFF.
Keep the wire harness away from the pump
drive coupling to prevent it from catching in
the coupling.
Confirm that the GE, TCV and FCV (magnet
valve) loads' direct current resistances are
within the normal range.
Confirm that the pump harnesses are not
shorted or broken.

CAUTION
If the manual controller emits an offensive
smell, smoke or catches fire, turn the power
switch OFF immediately and stop use.
Continued use could result in fire.
Advice
Always earth the FCV GND and FG terminals.
If the FCV GND terminal is not earthed, the
magnet valve will not operate, and fuel will
not be injected.
If the FG terminal is not earthed, the correct
injection quantity cannot be obtained.

- 53 -

ADJUSTMENT
4. INJECTION PUMP ADJUSTMENT OUTLINE
Preparation

See page 55

See page 56

See page 59

See page 65

See page 66

See page 66

See page 67

See page 67

Pre-stroke adjustment

Temporary full load injection quantity adjustment

Pump chamber pressure adjustment

See page 60

Final full load injection quantity adjustment

See page 62

Confirming the difference in delivery

See page 63

TPS adjustment (if installed)

See page 63

Timer stroke adjustment

See page 64

Timer stroke confirmation

See page 64

Pump chamber pressure confirmation

See page 65

Measuring the overflow quantity

Injection quantity confirmation

Np sensor output confirmation

Fuel temperature sensor confirmation

Magnet valve operation confirmation

Complete

- 54 -

ADJUSTMENT
Injection pump

Bolts (3)
M8x1.25, L = 35

5. INJECTION PUMP ADJUSTMENT

[1] Preparation
(1) Loosely attach the fixing stand to the pump
test stand, and then attach the injection
pump to the fixing stand.

Fixing stand

Tool name
Fixing stand

Part no
Remarks
105781-0361 For 5NP, 10NP
test stands

Fixing stand

105781-0610 For 7NP, 15NP

test stands

P-COVR-142

(2) Install the key to the drive shaft, align the

coupling with the key, and then install the
coupling on the shaft and fix it using the nut.

Coupling

Tool name
Coupling
Coupling

Part no
Remarks
157842-4620 Shaft dia 20
157842-4420 Shaft dia 17

P-COVR-143

Coupling

(3) Move the fixing stand and fit the coupling

teeth to the test stand drive coupling. Leave
approx 1 mm between the couplings.
Advice
Do not leave more than 1 mm between the
coupling and drive coupling.

Approx 1 mm or less

Drive coupling

P-COVR-144

Injection pump

Bolts (3)

(4) Turn the pump test stand flywheel using the

lever and confirm that the injection pump
rotates smoothly.
(5) Securely tighten the fixing stand installation
bolts and nuts, and the drive coupling's
socket head bolt to fix the injection pump to
the pump test stand.

Socket head bolt

Lever

Nut

Flywheel

P-COVR-145

- 55 -

ADJUSTMENT
[2] Pre-stroke adjustment
Only when pre-stroke is recorded in the
calibration data.
(1) Attach the dial gauge to the measuring
device.
Tool name
Part no
Remarks
Dial gauge
157954-4100
Measuring device 105782-8160
Dial gauge

Measuring device
P-COVR-146

Air bleeder bolt

Advice
Confirm that the gauge needle moves
smoothly.
(2) Remove the air bleeder bolt.
(3) Install the measuring device in the air bleeder
hole.

Measuring device
P-COVR-147

Chamber pressure hose

(4) Connect the fuel hose, the chamber

pressure measurement hose and the
overflow pipe to the injection pump. (Refer
to 'FUEL PIPING' on pages 49~50.)
(5) Connect the manual controller's wire
harness and intermediate harness to the
injection pump connectors. (Refer to the
wiring outline on page 51.)

Fuel hose

Overflow pipe

Manual controller wiring

Control sleeve position

target voltage setting dial

P-COVR-148

Control sleeve position

target voltage display

(6) Turn the controller's power switch ON.

(7) Position the IT control switch (timing control
closed loop/open loop switch) at OPEN.
(8) Turn the FCV (magnet valve) switch ON to
energize the magnet valve.
(9) Operate the U soll dial (control sleeve
position target voltage setting dial) so that
the U soll (V) display (control sleeve
position target voltage display) reads 2.8V.

Timing control closed loop /

open loop switch
Power switch FCV ON / OFF switch

P-COVR-149

- 56 -

ADJUSTMENT
(10) Supply fuel oil to the injection pump at the
specified pressure (20.0 kPa {0.2 kgf/cm2}).
(11) Rotate the pump test stand flywheel once
or twice in the specified direction of rotation
(refer to the calibration data) using the lever.
Confirm from the dial gauge that the plunger
lifts smoothly.
Advice
Fuel oil will flow from the measuring device
overflow port. Prepare an oil pan to catch
the fuel oil.

Lever

Dial gauge

Measuring device

P-COVR-150

(12) Rotate the pump test stand flywheel using

the lever to position the plunger in the
bottom dead center position.
Note:
The plunger's bottom dead center position is
the smallest reading indicated by the dial gauge
needle.
(13) Zero the dial gauge.
Advice
Confirm that fuel oil overflows from the
measuring device's overflow port.

Lever

Dial gauge

Fuel oil

P-COVR-151

(14) Slowly rotate the pump test stand's flywheel

in the specified direction of rotation (refer
to the calibration data) using the lever.
Read the dial gauge indication (ie, prestroke) when fuel oil stops flowing from the
measuring device overflow port.

Lever

Dial gauge

CAUTION

Measuring device

Shim

P-COVR-152

Always remove the lever from the flywheel

after rotating the flywheel. Operating the
pump test stand with the lever in place can
result in bodily injury or pump test stand
damage.
(15) If pre-stroke is not as specified, replace the
shim to adjust the 'K' dimension. (Refer to
pages 41~43 for K dimension
measurement.)
Note:
Pre-stroke adjustment is unnecessary if prestroke is not mentioned in the calibration data.

P-COVR-153

- 57 -

ADJUSTMENT
[3] Running-in operation

Fuel hoses

(1) Connect the fuel hoses to the injection pump.

(Refer to pages 49~50 for fuel piping.)
(2) Connect the new injection system piping to
the injection pump (refer to the calibration
data and page 51.)
(3) Connect the manual controller wire harness
and the intermediate harness to the injection
pump connectors. (Refer to page 51 for the
wiring outline.)
New injection
system piping

Manual controller
wiring

P-COVR-154

(4) Reconfirm that the coupling and fixing stand

bolts and nuts are securely tightened.
(5) Attach the measuring device to the injection
pump.

Fixing stand

Tool name
Part no
Measuring device 105782-8260

Remarks
For high
pressure

(6) Set the pump test stand fuel oil temperature

at 45+5 C.
Measuring device

P-COVR-155

(7) Turn the controller's power switch ON.

(8) Position the IT control switch (timing control
closed loop/open loop switch) at OPEN.
(9) Turn the FCV ON/OFF switch ON to
energize the magnet valve.

Timing control closed loop /

open loop switch

Power switch

FCV ON/OFF switch

P-COVR-156

Injection pump

P-COVR-157

(10) Set the pump test stand's fuel delivery

pressure to the specified pressure (20.0
kPa {0.2 kgf/cm2}).
(11) Drive the injection pump test stand at
approx 300 r/min in the specified direction
of rotation (refer to the calibration data) to
purge any air.
(12) Increase pump speed to approximately
1,300~1,500 r/min.
Set the control sleeve position target
voltage U soll (V) to the value
corresponding to pump speed. (Refer to
3-4 on data sheet.)

- 58 -

ADJUSTMENT
(13) Confirm that fuel oil is injected from the
nozzles.
(14) Confirm that no fuel leaks from the injection
pump fuel piping connections.

Injection pump

CAUTION
Stop operation immediately and check the
pump if fuel leaks, if there is no injection, or
if the pump makes unusual noises.

P-COVR-158

[4] Temporary full load injection

quantity adjustment

Control sleeve position target

voltage setting dial

TCV duty ratio dial

P-COVR-159

Control sleeve position target voltage setting dial

P-COVR-160

Dial gauge

Bracket

(15) After confirming that the pump is operating

normally, run-in the pump at approx 1,000
r/min for 30 minutes.

Cover

(1) Drive the injection pump at the specified

speed. (Refer to the calibration data.)
(2) Operate the control sleeve position target
voltage dial to set the specified U soll. (V:
refer to the calibration data.)
(3) Operate the TCV duty ratio dial to set the
specified TCV duty ratio (%) and frequency
(Hz); refer to the calibration data.
Advice
Because voltage is compensated in
accordance with the compensation
resistance number, each compensation
resistance's compensation voltage (refer to
the calibration data) must be added to the
specified U soll (V) when confirming the
full load injection quantity.
Example:
Specified U soll (V) +
compensation voltage U soll (V).
(4) Measure and record the full load injection
quantity.
(5) If the full load injection quantity is not as
specified in the calibration data, remove the
cover fixing bolt and fix the bracket together
with the cover (the bracket is fixed parallel
to the cover).
Tightening torque: 7.0~9.0 N.m
{0.7~0.9 kgf.m}
Tool name
Bracket

P-COVR-161

Part no
Remarks
157845-6100

(6) Position the dial gauge perpendicular to the

end of the cover and then zero the dial
gauge.

- 59 -

ADJUSTMENT
Dial gauge

GE actuator

P-COVR-162

TCV duty ratio dial

(7) Loosen the GE actuator screws so that the

GE actuator will move a little.
(8) Move the GE actuator in the driveshaft's axial
direction to adjust the full load injection
quantity. (When too small, move the GE
actuator towards the drive side; when too
large, move the GE actuator towards the
distributor head.) Record the measured
injection quantity and the corresponding dial
gauge reading to facilitate adjustment.
(9) After adjustment, remove the bracket and
retighten the cover and GE actuator screws.
Tightening torque: 7.0~9.0 N.m
{0.7~0.9 kgf.m}

[5] P u m p c h a m b e r p r e s s u r e
adjustment

Control sleeve position target voltage setting dial

P-COVR-163

(1) Drive the injection pump at the specified

speed (refer to the calibration data).
(2) Operate the control sleeve position target
voltage dial to set the specified U soll (V:
refer to the calibration data).
(3) Operate the TCV duty ratio dial to set the
specified TCV duty ratio (%) and frequency
(Hz); refer to the calibration data.
(4) Adjust the pump chamber pressure to the
specified pressure using the adjusting device
while observing the pressure display (refer
to the calibration data).
Tool name
Adjusting device

Adjusting device

P-COVR-164

Remarks

Advice
Refer to the following for procedures to
follow when the pump chamber pressure is
either too low or too high.
When pump chamber pressure is too low

Regulating valve
Plug

Attach the adjusting device to the regulating

valve.
Press the regulating valve plug in gradually
using the adjusting device to adjust the pump
chamber pressure. Do not press the plug in
too far.

Spring

Piston

Spring ring

Part no
157829-0820

P-COVR-165

- 60 -

ADJUSTMENT
Spring ring

Piston

When pump chamber pressure is too high

Spring

Stop the pump test stand and remove the

regulating valve.
Remove the spring ring using pliers and
remove the piston and spring.

Pliers

Tool name
Pliers

Part no
Remarks
157928-2920

P-COVR-166

Pushrod

Plug

Push the plug out to the end of the regulating

valve using the pushrod.

Tool name
Pushrod

Part no
Remarks
157829-5300

Note:
The pushrod (157829-5300) is part of the
inserter (157829-5220).

P-COVR-196

Insert the spring and piston into the regulating

valve.
Pressfit a new spring ring into the regulating
valve using the holder and a hammer.

Spring ring
Piston
Spring

Tool name
Holder

Part no
Remarks
157829-5200

Note:
The holder (157829-5200) is part of the inserter
(157829-5220).
Holder

P-COVR-167

Socket wrench

Screw the regulating valve into the pump

housing and tighten it using the socket wrench.
Tightening torque: 11.0~13.0 N.m
{1.1~1.3 kgf.m}

Tool name
Socket wrench

P-COVR-168

- 61 -

Part no
Remarks
157913-7000

ADJUSTMENT

Regulating valve
Plug

Adjust the pump chamber pressure to the

pressure specified in the calibration data as
described above. (See page 60.)

Spring

Piston

Spring ring

P-COVR-169

[6] Final full load injection quantity

adjustment

TCV duty ratio dial

(1) Drive the injection pump at the specified

speed (refer to the calibration data).
(2) Operate the control sleeve position target
voltage dial to set the specified U soll (V:
refer to the calibration data).
(3) Operate the TCV duty ratio dial to set the
specified TCV duty ratio (%) and frequency
(Hz); refer to the calibration data.

Control sleeve position target voltage setting dial

P-COVR-170

Advice
Because voltage is compensated in
accordance with the compensation
resistance number, each compensation
resistance's compensation voltage (refer to
the calibration data) must be added to the
specified U soll (V) when confirming the
full load injection quantity.
Example:
Specified U soll (V) +
compensation voltage U soll (V)

Control sleeve position target voltage display

Control sleeve position target voltage setting dial

P-COVR-171

(4) Measure the full load injection quantity and

confirm that it is as specified.

P-COVR-172

- 62 -

ADJUSTMENT

Minimum injection quantity

[7] Confirming the difference in

delivery

Maximum injection quantity

Delivery valve

Exchange if difference in
delivery is not as specified

P-COVR-173

Determine the difference in delivery between

the four cylinders' injection quantities as
described below, and then confirm that it is as
specified in the calibration data.
Maximum injection quantity minimum injection quantity
= difference in delivery (cm3)
Advice
If the difference in delivery is not as
specified, interchange the delivery valves of
the cylinders with the largest and smallest
injection quantities, measure the fuel
injection quantities and recalculate the
difference in delivery. If still not as specified,
replace the delivery valves with new ones
and remeasure the difference in delivery.

[8] TPS adjustment

Control sleeve position target voltage setting dial

If installed

TCV duty ratio dial

(1) Drive the injection pump at the specified

speed (refer to the calibration data).
(2) Operate the control sleeve position target
voltage dial to set the specified U soll (V:
refer to the calibration data).
(3) Operate the TCV duty ratio dial to set the
specified TCV duty ratio (%) and frequency
(Hz); refer to the calibration data.
P-COVR-174

(4) Read the TPS output voltage at a timer

stroke of 0 mm.
(5) If the TPS output voltage is not as specified,
replace the TPS standard point shim.
Shim part no

Thickness (mm)

146603-1100

1.2

Outside, Inside ()
17.5

7.5

Note:
A TPS standard point shim of thickness 1.2 mm
is assembled as standard.

TPS standard point shim

P-COVR-175

- 63 -

ADJUSTMENT
[9] Timer stroke adjustment
(1) Drive the injection pump at the specified
speed (refer to the calibration data).
(2) Operate the control sleeve position target
voltage dial to set the specified U soll (V:
refer to the calibration data).
(3) Operate the TCV duty ratio dial to set the
specified duty ratio (%) and frequency (Hz);
refer to the calibration data.

TCV duty ratio dial

Control sleeve position target

voltage setting dial

P-COVR-176

(4) Read the timer stroke.

Measuring device

P-COVR-177

(5) If the timer stroke is not as specified, replace

the timer stroke adjusting shim until the timer
stroke is as specified.

Timer stroke adjusting shim

Shim part no

Thickness (mm)

Shim part no

146603-0070
146603-0080
146603-0090

0.6
0.7
0.9

146603-1000
146603-1100
146603-3600

Thickness (mm)
1.0
1.2
2.4

P-COVR-178

[10]Timer stroke confirmation

TCV duty ratio dial

(1) Operate the control sleeve position target

voltage dial to set the specified U soll (V:
refer to the calibration data).
(2) Operate the TCV duty ratio dial to set the
specified TCV duty ratio (%) and frequency
(Hz); refer to the calibration data.

Control sleeve position target

voltage setting dial
P-COVR-179

- 64 -

ADJUSTMENT

Measuring device

P-COVR-180

(3) Drive the injection pump at each specified

speed (refer to the calibration data) and
confirm that each timer stroke is as specified.
(4) If a TPS is installed, confirm that the TPS
output is as specified.
Advice
Confirm that the timer stroke is 0 at the
specified speed and U soll, and at a TCV
duty ratio of 0%.
If the timer stroke exceeds 0, measure the
TCV resistance. If not as specified, replace
the TCV.

[11]P u m p c h a m b e r p r e s s u r e
confirmation

TCV duty ratio dial

(1) Operate the control sleeve position target

voltage dial to set the specified U soll (V:
refer to the calibration data).
(2) Operate the TCV duty ratio dial to set the
specified duty ratio (%) and frequency (Hz);
refer to the calibration data.
Control sleeve position target
voltage setting dial

P-COVR-181

(3) Drive the injection pump at each specified

speed (refer to the calibration data) and
confirm that each pump chamber pressure
is as specified.

Pressure gauge

P-COVR-182

[12]Measuring the overflow quantity

TCV duty ratio dial

(1) Operate the control sleeve position target

voltage dial to set the specified U soll (V:
refer to the calibration data).
(2) Operate the TCV duty ratio dial to set the
specified TCV duty ratio (%) and frequency
(Hz); refer to the calibration data.

Control sleeve position

target voltage setting dial
P-COVR-183

- 65 -

ADJUSTMENT
(3) Drive the injection pump at the specified
speed (refer to the calibration data) and
confirm that the overflow quantity is as
specified.
Tool name
Part no
Remarks
Measuring cylinder 157970-0500

Measuring cylinder
P-COVR-184

[13]Injection quantity confirmation

TCV duty ratio dial

Control sleeve position target

voltage setting dial

(1) Operate the control sleeve position target

voltage dial to set the specified U soll (V:
refer to the calibration data).
(2) Operate the TCV duty ratio dial to set the
specified TCV duty ratio (%) and frequency
(Hz); refer to the calibration data.

P-COVR-185

(3) Drive the injection pump at the specified

speed (refer to the calibration data) and
confirm that the injection quantities are as
specified for each specified speed.

Injection pump

P-COVR-186

[14]N p s e n s o r ( p i c k u p ) o u t p u t
confirmation

TCV duty ratio dial

(1) Operate the control sleeve position target

voltage dial to set the specified U soll (V:
refer to the calibration data).
(2) Operate the TCV duty ratio dial to set the
specified TCV duty ratio (%) and frequency
(Hz); refer to the calibration data.
Control sleeve position target
voltage setting dial

P-COVR-187

- 66 -

ADJUSTMENT
(3) Drive the injection pump at the specified
speed (refer to the calibration data) and
confirm that the Np sensor output is as
specified for each specified speed.

Np sensor

P-COVR-188

[15]F u e l t e m p e r a t u r e s e n s o r
confirmation

TCV duty ratio dial

(1) Operate the control sleeve position target

voltage dial to set the specified U soll (V:
refer to the calibration data).
(2) Operate the TCV duty ratio dial to set the
specified TCV duty ratio (%) and frequency
(Hz); refer to the calibration data.
Control sleeve position target
voltage setting dial

P-COVR-189

(3) Drive the injection pump at the specified

speed (refer to the calibration data) and
confirm that the fuel temperature sensor's
displayed temperature is as specified for
each specified speed.

P-COVR-190

[16]M a g n e t v a l v e o p e r a t i o n
confirmation

TCV duty ratio dial

(1) Operate the control sleeve position target

voltage dial to set the specified U soll (V:
refer to the calibration data).
(2) Operate the TCV duty ratio dial to set the
specified TCV duty ratio (%) and frequency
(Hz); refer to the calibration data.
Control sleeve position
target voltage setting dial
P-COVR-191

- 67 -

ADJUSTMENT
(3) Drive the injection pump at the specified
speed (refer to the calibration data).
(4) Confirm that nozzle injection stops when the
FCV (magnet valve) ON/OFF switch is
turned OFF.
Advice
Confirm no nozzle injection for a short time
(2~3 seconds).

Magnet valve

P-COVR-192

[17]Rubber seal replacement

(1) After completing adjustment, remove the
harness connectors' rubber seals using a
piece of wire, etc, and replace them with new
ones.

Rubber seals
P-COVR-193

(2) Remove the TCV connector's rubber seal

cap using a piece of wire and replace the
rubber seal with a new one.

Rubber seal

Rubber seal cap

P-COVR-194

- 68 -

TIGHTENING TORQUES

T = 10 ~ 13 (1 ~ 1.3)

SW 14
T = 44 ~ 54 (4.5 ~ 5.5)

T = 7 ~ 10
(0.7 ~ 1)

SW19
T = 20 ~ 29 (2 ~ 3)

SW17
T = 20 ~ 29 (2 ~ 3)

SW10
T = 10 ~ 13 (1 ~ 1.4)

SW24
T = 20 ~ 25 (2 ~ 2.5)

T = 10 ~ 14 (1 ~ 1.4)
T = 59 ~ 78
(6 ~ 8)

SW21
T = 20 ~ 25 (2 ~ 2.5)
T = 7 ~ 10 (0.7 ~ 1)

SW12
T = 20 ~ 26 (2 ~ 2.6)

T = 7 ~ 10 (0.7 ~ 1)

T = 7 ~ 10 (0.7 ~ 1)

Unit: N.m {kgf.m}

P-COVR-195

- 69 -

PART NUMBER EXPLANATION

1. INJECTION PUMP ASSEMBLY NUMBER
1

1 : VE type injection pump

2 : Number of cylinders
0 4 cylinders
1 6 cylinders
3 : Plunger diameter
8 8
6 11
9 9
1 11
0 10 2 12
5 11
4 : Proper number
5 : Suffix

2. BOSCH TYPE NUMBER

NP - VE
1
1
2
3
4
5

R NP
7

:
:
:
:
:

Manufactured by Bosch Automotive Systems Corporation

VE type injection pump
Number of cylinders
Plunger diameter
E: Electronic governor
F: Mechanical governor
6 : Maximum controlled governor speed (r/min)
7 : Direction of pump rotation
R: Clockwise (viewed from drive side)
L: Counterclockwise (viewed from drive side)
8 : Proper number

- 70 -

Pub. No: EE14E-11102

FUEL INJECTION PUMP MODEL COVEC-F
Service Manual
Repair Service & Maintenance
Printing: January 2001
Published by:
Bosch Automotive Systems Corporation
Service Department
Printed in Japan
C Copyright 2001,
Bosch Automotive Systems Corporation
200-24
Printed on recycled paper

WPGES-01