GENERAL

PUMP MARCH 2004

S.I. 447 1 / 13

COVEC-F HARNESS AND CONNECTOR

INSTALLATION STANDARDS
This service information describes the standards for COVEC-F harnesses and connectors at
COVEC-F installation. These standards must be observed when repairing the injection pump.

1. APPLICABLE PUMP ASSEMBLY PART NUMBERS

RBAJ part no. Bosch part no.

104700-9141 9 460 614 829

104700-9152 9 460 614 830

104700-9162 9 460 614 826

104700-9171 9 460 614 849

2. INSTALLATION STANDARDS
[1] Pump assembly no. 104700-9141
(1) TCV connector assembly
(1) Do not twist the portion of the GE harness indicated in the figure below.
Advice
Position the 15-pin connector as shown.
(2) When connecting the connector, route the TCV harness in the direction shown by the
arrows in the figure below.

Do not twist this length of GE harness. 15-pin connector

TCV harness

TCV harness

Sales Automotive Aftermarket Division Printed in Japan

Bosch K.K.
 MARCH 2004
S.I. 447 2 / 13
Advice
After completing all of the procedures below, ensure no lead wires are exposed after
routing the harnesses (except for the FCV).
(2) Binding the harnesses
(1) Position the harnesses and connectors as shown in the figure below and then fix them
using binders as shown below. (The binders are key no. 530 in the part list.)
(2) Cut off any surplus binder 2 mm or less from the clip.
(3) Attach a cover to the connector for GE, FCV, TCV and Q adjustment.

2 mm or less

75
ox
Connector
pr
Ap Cut off any (for GE, FCV, TCV and Q adjustment)
excess binder
7510 mm

Binder

105+11
-9 mm

105+11
-9 mm

Attach cover to connector

TPS
Np

(3) Installing the corrugated tube (key no. 536)

(1) Position the corrugated tubes' slits as shown in the figure below.
(2) Position the corrugated tube against the binders and fix it using vinyl tape at the positions
shown.
Note:
The vinyl tape is key no. 535 in the part list.
(3) Confirm the dimension and then fix the tube using vinyl tape at .

Approx 20 mm Approx 30 mm
Vinyl tape Vinyl tape

34510 mm
Outside end of binder
End of corrugated tube
End of corrugated tube must
contact binder

34510
45
25 mm or less 10 mm or less 45

Width of tape wrapping

Position corrugated tube slit within

45 of the bottom of the harness.
 MARCH 2004
S.I. 447 3 / 13
(4) Fixing the harnesses
(1) Ensure that the distance between the binder and the clip is 32010 mm.
(2) Fix the clip (key no. 551 in the part list) using the socket head bolt (key no. 552, 553 in
the part list).
Advice
Adjust the length of within the tolerance so that the TPS and Np harness at A is not
excessively loose, then fix using the clip.
(3) Bind the GE cable and the FCV harness using the binder (key no. 530 in the part list) at .
(4) Bind the TPS harness and the Np harness using the binder (key no. 530 in the part list) at .
Advice
Attach the binder after ensuring that the TPS cover is not loose.

Binder

Clip 32010 mm
A Outside end of binder
Binder Socket head bolt
T = 9.8 ~ 13.7 Nm Binder
{1.0 ~ 1.4 kgfm}
mm

Binder
15

32010 mm
5~

TPS cover

(5) Vinyl tape

Wrap the vinyl tape (key no. 535 in the part list) around the corrugated tube as shown in the
figure below.

25010 mm
2510 mm (20 mm) (20 mm)
1
0
m
m

Vinyl tape
 MARCH 2004
S.I. 447 4 / 13
(6) Marking the harnesses
(1) Ensure the corrugated tube is not twisted when marking it.
(2) Use an industrial grade indelible white paint (or a white indelible marking pen).
(3) Mark at the two locations indicated in the figure below (viewed from the side of the pump
and the top of the pump). The markings must be the dimensions shown and approx. 5 mm
wide.

White marking
Width 5 mm (location 2/2)

2 - 205 mm
From end of taping End of taping

White marking
Width 5 mm (location 1/2)

[2] Pump assembly no. 104700-9152

(1) TCV connector assembly
(1) Do not twist the portion of the GE harness indicated in the figure below.
Advice
Position the 15-pin connector as shown.
(2) When connecting the connector, route the TCV harness in the direction shown by the
arrows in the figure below.

Do not twist this length of GE harness. 15-pin connector

TCV harness

TCV harness
 MARCH 2004
S.I. 447 5 / 13
Advice
After completing all of the procedures below, ensure no lead wires are exposed after
routing the harnesses (except for the FCV).
(2) Binding the harnesses
(1) Position the harnesses and connectors as shown in the figure below and then fix them
using binders as shown below. (The binders are key no. 530 in the part list.)
(2) Cut off any surplus binder 2 mm or less from the clip.
(3) Attach a cover to the connector for GE, FCV, TCV and Q adjustment.

2 mm or less

75
ox Connector
pr
(for GE, FCV, TCV and Q adjustment)
Ap

Cut off any

excess binder
7510 mm

Binder

85+11
-9 mm

85+11
-9 mm

Attach cover to connector

TPS
Np

(3) Installing the corrugated tube (key no. 536)

(1) Position the corrugated tubes' slits as shown in the figure below.
(2) Position the corrugated tube against the binders and fix it using vinyl tape at the positions
shown.
Note:
The vinyl tape is key no. 535 in the part list.
(3) Confirm the dimension and then fix the tube using vinyl tape at .

Approx 20 mm Approx 30 mm
Vinyl tape Vinyl tape

26510 mm
Outside end of binder
End of corrugated tube
End of corrugated tube must
contact binder

45
25 mm or less 10 mm or less 45

Width of tape wrapping

Position corrugated tube slit within

45 of the bottom of the harness.
 MARCH 2004
S.I. 447 6 / 13
(4) Fixing the harnesses
(1) Ensure that the distance between the binder and the clip is 24110 mm.
(2) Fix the clip (key no. 551 in the part list) using the socket head bolt (key no. 552, 553 in
the part list).
Advice
Adjust the length of within the tolerance so that the TPS and Np harness at A is not
excessively loose, then fix using the clip.
(3) Bind the GE cable and the FCV harness using the binder (key no. 530 in the part list) at .
(4) Bind the TPS harness and the Np harness using the binder (key no. 530 in the part list) at .
Advice
Attach the binder after ensuring that the TPS cover is not loose.

Binder

Clip 24110 mm
A Outside end of binder
Binder Socket head bolt
T = 9.8 ~ 13.7 Nm Binder
{1.0 ~ 1.4 kgfm}
mm

Binder
15

24010 mm
5~

TPS cover

(5) Vinyl tape

Wrap the vinyl tape (key no. 535 in the part list) around the corrugated tube as shown in the
figure below.

17010 mm
2510 mm (20 mm) (20 mm)
1
0
m
m

Vinyl tape
 MARCH 2004
S.I. 447 7 / 13
(6) Marking the harnesses
(1) Ensure the corrugated tube is not twisted when marking it.
(2) Use an industrial grade indelible white paint (or a white indelible marking pen).
(3) Mark at the two locations indicated in the figure below (viewed from the side of the pump
and the top of the pump). The markings must be the dimensions shown and approx. 5 mm
wide.

White marking
Width 5 mm
(location 2/2)

2 - 205 mm
From end of taping End of taping

White marking
Width 5 mm (location 1/2)

[3] Pump assembly no. 104700-9162

(1) TCV connector assembly
(1) Do not twist the portion of the GE harness indicated in the figure below.
Advice
Position the 15-pin connector as shown.
(2) When connecting the connector, route the TCV harness in the direction shown by the
arrows in the figure below.

Do not twist this length of GE harness. 15-pin connector

TCV harness

TCV harness
 MARCH 2004
S.I. 447 8 / 13
Advice
After completing all of the procedures below, ensure no lead wires are exposed after
routing the harnesses (except for the FCV).
(2) Binding the harnesses
(1) Position the harnesses and connectors as shown in the figure below and then fix them
using binders as shown below. (The binders are key no. 530 in the part list.)
(2) Cut off any surplus binder 2 mm or less from the clip.
(3) Attach a cover to the connector for GE, FCV, TCV and Q adjustment.

2 mm or less

75
ox Connector
pr
Cut off any
(for GE, FCV, TCV and Q adjustment)
Ap

excess binder
24010 mm

Binder

185+11
-9 mm

185+11
-9 mm

Attach cover to connector

TPS
Np

(3) Installing the corrugated tube (key no. 536)

(1) Position the corrugated tubes' slits as shown in the figure below.
(2) Position the corrugated tube against the binders and fix it using vinyl tape at the positions
shown.
Note:
The vinyl tape is key no. 535 in the part list.
(3) Confirm the dimension and then fix the tube using vinyl tape at .

Approx 20 mm Approx 30 mm
Vinyl tape Vinyl tape

34510 mm
Outside end of binder
End of corrugated tube
End of corrugated tube must
contact binder

45
25 mm or less 10 mm or less
45

Width of tape wrapping

Position corrugated tube slit within

45 of the bottom of the harness.
 MARCH 2004
S.I. 447 9 / 13
(4) Fixing the harnesses
(1) Ensure that the distance between the binder and the clip is 32010 mm.
(2) Fix the clip (key no. 551 in the part list) using the socket head bolt (key no. 552, 553 in
the part list).
Advice
Adjust the length of within the tolerance so that the TPS and Np harness at A is not
excessively loose, then fix using the clip.
(3) Bind the GE cable and the FCV harness using the binder (key no. 530 in the part list) at .
(4) Bind the TPS harness and the Np harness using the binder (key no. 530 in the part list) at .
Advice
Attach the binder after ensuring that the TPS cover is not loose.

Binder

Clip 32010 mm
A Outside end of binder
Binder Socket head bolt
T = 9.8 ~ 13.7 Nm Binder
{1.0 ~ 1.4 kgfm}
mm

Binder
15

32010 mm
5~

TPS cover

(5) Vinyl tape

Wrap the vinyl tape (key no. 535 in the part list) around the corrugated tube as shown in the
figure below.

25010 mm
2510 mm (20 mm) (20 mm)
1
0
m
m

Vinyl tape
 MARCH 2004
S.I. 447 10 / 13
(6) Marking the harnesses
(1) Ensure the corrugated tube is not twisted when marking it.
(2) Use an industrial grade indelible white paint (or a white indelible marking pen).
(3) Mark at the two locations indicated in the figure below (viewed from the side of the pump
and the top of the pump). The markings must be the dimensions shown and approx. 5 mm
wide.

White marking
Width 5 mm (location 2/2)
(location 2/2)

2 - 205 mm
From end of taping
End of taping

White marking
Width 5 mm (location 1/2)

(7) Installing the binders

(1) After installing the tape, align the binder (key no. 530 in the part list) with the end of the tape
and tighten.
(2) Cut off any surplus binder 2 mm or less from the clip.

Binder

Binder

End of binder

End of taping
 MARCH 2004
S.I. 447 11 / 13
[4] Pump assembly no. 104700-9171
(1) TCV connector assembly
(1) Do not twist the portion of the GE harness indicated in the figure below.
Advice
Position the 15-pin connector as shown.
(2) When connecting the connector, route the TCV harness in the direction shown by the
arrows in the figure below.

Do not twist this length of GE harness. 15-pin connector

TCV harness

TCV harness

Advice
After completing all of the procedures below, ensure no lead wires are exposed after
routing the harnesses (except for the FCV).
(2) Binding the harnesses
(1) Position the harnesses and connectors as shown in the figure below and then fix them
using binders as shown below. (The binders are key no. 530 in the part list.)
(2) Cut off any surplus binder 2 mm or less from the clip.
(3) Attach a cover to the connector for GE, FCV, TCV and Q adjustment.
2 mm or less

75
ox

Connector
pr

(for GE, FCV, TCV and Q adjustment)

Ap

Cut off any

excess binder
30010 mm

Binder

235+11
-9 mm

225+11
-9 mm

Np
Attach cover to connector

TPS
 MARCH 2004
S.I. 447 12 / 13
(3) Installing the corrugated tube (key no. 536)
(1) Position the corrugated tubes' slits as shown in the figure below.
(2) Position the corrugated tube against the binders and fix it using vinyl tape at the positions
shown.
Note:
The vinyl tape is key no. 535 in the part list.
(3) Confirm the dimension and then fix the tube using vinyl tape at .

Approx 20 mm Approx 30 mm
Vinyl tape Vinyl tape

28510 mm
Outside end of binder
End of corrugated tube
End of corrugated tube must
contact binder

45
25 mm or less 10 mm or less
45

Width of tape wrapping

Position corrugated tube slit within

45 of the bottom of the harness.

(4) Fixing the harnesses

(1) Ensure that the distance between the binder and the clip is 26010 mm.
(2) Fix the clip (key no. 551 in the part list) using the socket head bolt (key no. 552, 553 in
the part list).
Advice
Adjust the length of within the tolerance so that the TPS and Np harness at A is not
excessively loose, then fix using the clip.
(3) Bind the GE cable and the FCV harness using the binder (key no. 530 in the part list) at .
(4) Bind the TPS harness and the Np harness using the binder (key no. 530 in the part list) at .
Advice
Attach the binder after ensuring that the TPS cover is not loose.

Binder

26010 mm
A Clip Outside end of binder
Binder Socket head bolt
T = 9.8 ~ 13.7 Nm
Binder
{1.0 ~ 1.4 kgfm}
mm

Binder
15

26010 mm
5~

TPS cover
 MARCH 2004
S.I. 447 13 / 13
(5) Vinyl tape
Wrap the vinyl tape (key no. 535 in the part list) around the corrugated tube as shown in the
figure below.

19010 mm
2510 mm (20 mm) (20 mm)
1
0
m
m

Vinyl tape

(6) Marking the harnesses

(1) Ensure the corrugated tube is not twisted when marking it.
(2) Use an industrial grade indelible white paint (or a white indelible marking pen).
(3) Mark at the two locations indicated in the figure below (viewed from the side of the pump
and the top of the pump). The markings must be the dimensions shown and approx. 5 mm
wide.

White marking Width 5 mm (location 2/2)

2 - 205 mm
From end of taping End of taping

White marking
Width 5 mm (location 1/2)