FOR AVM - 10

INJECTION PUMP TEST SPECIFICATIONS 096500-5020

Injection Pump 096500-5020 (VE4/11E2200RND502) Manufacturer MAZDA

Governor Type Electronic control Vehicle Model 626 / 323

Timer Electronic control Engine Type RF-TDI

Rotation Clockwise viewed from drive side Rated Voltage 14 ± 0.1 V

Injection Order A-B-C-D Dimension KF (mm) 7.3 ± 0.1
Injection Interval 90° Dimension K (mm) 3.7 ± 0.1
Pump Select Switch No. (ECD Controller) 2

1. TEST CONDITIONS
1) Nozzle 093400-7110 (DLLA0P711) 4) Feed Pressure 0.2 kg/cm2
2) Nozzle Opening Pressure 175 ± 1 kg/cm2 5) High Pressure Pipe Ø1.8 X Ø6 X 840 mm
3) Test Oil SAE J967 (ISO4113) 6) Fuel Temperature 40 - 43 °C (104 - 109.4 °F)

2. FUEL CUT VALVE CHECK (Power source : Over 12 V, Over 3.0 A)

Condition
Pump
Speed Applied Applied Check point Remarks Time to check
(rpm) voltage current
(V) (A)

0 13.0 ± 0.3 2.9 Operation sounds of SPV and —

FCV by turn on / off power
Fuel cut valve
388 13.0 ± 0.3 2.9 Fuel injection Max. injection quantity under idling check should
be done within
25 seconds
388 0 2.9 Instant stop of fuel injection Stop pump with SPV turn off after
checking instant stop of fuel injection

3. INSPECTION OF Ne SENSOR
ECD CONTROLLER SETTING
Sensor Output
Pump Speed Voltage
Display Injection Duty Ratio Pump Select Remarks
(rpm) (V)
Selector Quantity Command Switch
Command

50 Np B40 — REC OFF 0.1 or more —

4. INSPECTION OF FUEL TEMPERATURE SENSOR

ECD CONTROLLER SETTING
Pump Speed Sensor Resistance
Display Injection Duty Ratio Pump Select Remarks
(rpm) (k )
Selector Quantity Command Switch
Command

Fuel
— Temperature — — REC OFF 1.85 ± 1.5

5. BREAK-IN DRIVE
ECD CONTROLLER SETTING
Pump Speed
Display Injection Duty Ratio Pump Select Condition Remarks
(rpm)
Selector Quantity Command Switch
Command

No fuel leaks, no
abnormal noise, Drive more than
1200 SPL A78 — REC OFF and no abnormal 5 minutes.
temperature rising.

2003.03.20
FOR AVM - 10 096500-5020

6. ADJUSTMENT OF TIMER (Always stop pump when changing the first digit of injection quantity command.)

ECD CONTROLLER SETTING

Pump Speed Timer Stroke
Display Injection Duty Ratio Pump Select Remarks
(rpm) (mm)
Selector Quantity Command Switch
Command

Internal Pressure
2000 Timer Adjust 000 — REC OFF 14.3 ± 0.35 9.24 ± 0.20 kgf/cm2
Overflow Quantity
750 - 1167 cc/min
Internal Pressure
1250 Timer Adjust 100 — REC OFF 14.3 ± 0.35 7.7 ± 1.1 kgf/cm2
200 — REC OFF 3.8 ± 3.0

300 — REC OFF 0

200 Timer Adjust 400 — REC OFF 3.2 or more

When the correction value is raised by 1 level, the injection

7. ADJUSTMENT OF FUEL DELIVERY quantity is increased approx. 0.04 - 0.06 cc/200st.

Pump ECD CONTROLLER SETTING Target Quantity Target Quantity Max. Outlet Fuel
Speed [ND - CPS] [AVM - 10] Spread Guard Value Temperature
Display First Duty Ratio Pump Select
(rpm) Digit Command (cc/200st·cyl.) (cc/200st·cyl.) In Delivery
(cc)
(upper - lower) (C°)
Selector Switch

200 Q Adjust 0 0 REC OFF 5.76 ± 0.90 6.27 ± 0.90 — 9D1 - 971 40.0 ± 5.0
200 Q Adjust 1 0 REC OFF 17.54 ± 0.64 19.80 ± 0.64 1.4 A55 - 9F5 40.0 ± 5.0
388 Q Adjust 2 0 REC OFF 2.16 ± 0.36 2.09 ± 0.36 0.5 980 - 920 40.0 ± 5.0
388 Q Adjust 3 0 REC OFF 8.20 ± 0.36 8.27 ± 0.36 — 9F2 - 992 40.0 ± 6.0
500 Q Adjust 4 0 REC OFF 2.78 ± 0.36 2.86 ± 0.36 — 986 - 926 40.0 ± 6.0
500 Q Adjust 5 0 REC OFF 9.26 ± 0.36 9.39 ± 0.36 0.5 A0D - 9AD 42.0 ± 7.0
750 Q Adjust 6 0 REC OFF 3.10 ± 0.34 2.95 ± 0.34 — 983 - 923 42.0 ± 7.0
750 Q Adjust 7 0 REC OFF 12.64 ± 0.34 12.91 ± 0.34 0.5 A84 - A24 46.0 ± 7.0
1250 Q Adjust 8 0 REC OFF 2.98 ± 0.32 3.07 ± 0.32 — 95D - 8FD 42.0 ± 7.0
1250 Q Adjust 9 0 REC OFF 11.90 ± 0.32 11.79 ± 0.32 0.5 A9F - A3F 46.0 ± 7.0
2000 Q Adjust A 0 REC OFF 2.58 ± 0.36 2.50 ± 0.36 — 910 - 890 49.0 ± 5.0
2000 Q Adjust B 0 REC OFF 11.24 ± 0.36 11.33 ± 0.36 0.5 AB8 - A38 52.0 ± 7.0
NOTE : Select "REC ON" position every time when fixing the final correction value at each point.
First Digit : First digit (The leftest of 3 digits) of "Injection Quantity Command Value" input switch.

8. PRESETTING FOR CAM ANGLE ADJUSTMENT

ECD CONTROLLER SETTING
Pump Target Quantity Target Quantity
Display Injection Quantity Duty Pump
Speed [ND - CPS] [AVM - 10] Remarks
Selector Command Ratio Select
(rpm) (cc/200st·cyl.) (cc/200st·cyl.)
Command Switch
First Second Third
digit digit digit
0 SPV OFF 9 7 2 100 REC OFF — —
388 SPL 9 7 2 100 REC OFF 3.78 ± 0.20 4.02 ± 0.20
Adjust 2nd. and 3rd.digits
388 SPV OFF 9 100 REC OFF 3.78 ± 0.20 4.02 ± 0.20 to get"Target Quantity",
then turn to "REC ON"
position
388 SPL 9 100 REC ON 3.78 ± 0.20 4.02 ± 0.20 Re-measurement
When the correction value is raised by 1 level, the injection quantity is increased approx. 0.04 - 0.06 cc/200st.
FOR AVM - 10 096500-5020

9. ADJUSTMENT OF CAM ANGLE

ECD CONTROLLER SETTING

Pump Speed Display Injection Quantity Duty Ratio Pump Target Angle
Standard Remarks
(rpm) Selector Command Command Select (°CA)
Switch
First Second Third
digit digit digit
Recorded Adjust 2nd. and 3rd.
Cam REC injection digits to get "Target
388 Angle 0 0 0 100 OFF 4.28 ± 0.50
command Angle"

Record the final

Cam REC correction value
388 0 100 — —
Angle OFF " "

NOTE : Select "REC ON" position every time when recording the final correction value.
: Never forget removing pressure sensor from piping.

10. RECONFIRMATION OF FUEL DELIVERY

Pump ECD CONTROLLER SETTING Target Quantity Target Quantity Max. Outlet Fuel
Speed [ND - CPS] [AVM - 10] Spread Guard Value Temperature
Display First Duty Ratio Pump Select
(rpm) (cc/200st·cyl.) (cc/200st·cyl.) In Delivery
(cc)
(upper - lower) (C°)
Selector Digit Command Switch

200 Confirm 0 0 REC OFF 5.76 ± 0.90 6.27 ± 0.90 — 9D1 - 971 40.0 ± 5.0
200 Confirm 1 0 REC OFF 17.54 ± 0.64 19.80 ± 0.64 1.4 A55 - 9F5 40.0 ± 5.0
388 Confirm 2 0 REC OFF 2.16 ± 0.36 2.09 ± 0.36 0.5 980 - 920 40.0 ± 5.0
388 Confirm 3 0 REC OFF 8.20 ± 0.36 8.27 ± 0.36 — 9F2 - 992 40.0 ± 6.0
500 Confirm 4 0 REC OFF 2.78 ± 0.36 2.86 ± 0.36 — 986 - 926 40.0 ± 6.0
500 Confirm 5 0 REC OFF 9.26 ± 0.36 9.39 ± 0.36 0.5 A0D - 9AD 42.0 ± 7.0
750 Confirm 6 0 REC OFF 3.10 ± 0.34 2.95 ± 0.34 — 983 - 923 42.0 ± 7.0
750 Confirm 7 0 REC OFF 12.64 ± 0.34 12.91 ± 0.34 0.5 A84 - A24 46.0 ± 7.0
1250 Confirm 8 0 REC OFF 2.98 ± 0.32 3.07 ± 0.32 — 95D - 8FD 42.0 ± 7.0
1250 Confirm 9 0 REC OFF 11.90 ± 0.32 11.79 ± 0.32 0.5 A9F - A3F 46.0 ± 7.0
2000 Confirm A 0 REC OFF 2.58 ± 0.36 2.50 ± 0.36 — 910 - 890 49.0 ± 5.0
2000 Confirm B 0 REC OFF 11.24 ± 0.36 11.33 ± 0.36 0.5 AB8 - A38 52.0 ± 7.0

11. CHECK POINT

ECD CONTROLLER SETTING
Pump Injection Quantity Injection Quantity Outlet Fuel
Speed Display Injection Duty Ratio Pump Select [ND - CPS] [AVM - 10] Temperature
(rpm) Selector Quantity Command Switch (cc/200st·cyl.) (cc/200st·cyl.) (C°)
Command

600 Confirm C00 — REC OFF 6.86 ± 0.50 7.12 ± 0.50 44.0 ± 11.0
2300 Confirm D00 — REC OFF 2.40 or more 2.40 or more 56.0 ± 10.0
2550 Confirm E00 — REC OFF 3.54 ± 1.00 3.52 ± 1.00 55.0 ± 9.0
Timing mark re-marking position : Based on cylinder A , cam lift distance (plunger) should be 2.87 mm