Bosch Ve Fuel Injection Pump Manuall
Bosch VE Fuel Injection Pump Manual
Bosch VE Fuel Injection Pump Manual
The Bosch VE fuel injection pump is a distributor-type pump that can be found on many diesel engines. It is used to deliver pressurized fuel to the injectors, as well as to control the injection timing and the amount of fuel injected. The Bosch VE pump has a code designation on the side that indicates the manufacturer, the type, the number of cylinders, the plunger diameter, the governor, the RPM number, the design symbol, the direction of rotation, and the serial number. For example, NP-VE 4/11 F 2400 A R NP 12 means that the pump is made by Diesel Kiki, it has four cylinders and 11 mm plungers, it has a mechanical governor with a maximum speed of 2400 RPM, it has a design symbol A, it rotates clockwise, and it has a serial number NP 12.
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The main components of the Bosch VE pump are shown in Figure 1. They include:
A drive shaft that connects to the engine and drives the cam plate, the fuel-supply pump, and the governor flyweight drive gear.
A cam plate that has face cams corresponding to the number of cylinders. The face cams contact the rollers and cause the cam plate and plunger to move back and forth in the plunger bore.
A plunger that is attached to the cam plate and rotates with it. The plunger has a helical groove that determines the injection timing and duration.
A distributor head that houses the plunger bore and has a delivery valve for each cylinder. The delivery valve opens and closes to allow fuel to flow to the injector.
A fuel-supply pump that is a positive displacement, vane-type pump. It draws fuel from the tank and sends it to the distributor plunger and the automatic advance-timing device.
An automatic advance-timing device that adjusts the injection timing according to the fuel-supply pump pressure. As the pressure increases, the piston moves the roller ring opposite to the drive shaft rotation, advancing the injection timing.
A control lever that regulates the amount of fuel injected by changing the position of the control collar. The control collar determines how much of the plunger stroke is effective for injection.
A governor that controls the engine speed by varying the position of the control lever. The governor consists of flyweights, a flyweight carrier, a tensioning lever, a control rod, and a control spring.
An overflow valve that maintains a constant pressure in the fuel system by returning excess fuel to the tank.
A fuel-cut solenoid that shuts off the fuel supply when the ignition is turned off.
Figure 1: Cutaway of Bosch VE pump showing main components
How to Service and Repair Bosch VE Pump
The Bosch VE pump is designed to be reliable and durable, but it may require some service and repair over time. Some common problems that may occur with the Bosch VE pump are:
Leaking or worn delivery valves
Sticking or worn plungers
Malfunctioning or damaged automatic advance-timing device
Defective or dirty fuel-supply pump
Incorrect or worn control collar
Loose or broken governor components
Clogged or damaged overflow valve
Faulty or stuck fuel-cut solenoid
To service and repair these problems, you will need a Bosch VE pump manual that provides detailed instructions on how to disassemble, inspect, test, adjust, and reassemble the pump. You will also need some special tools and equipment, such as a torque wrench, a dial indicator, a pressure gauge, a vacuum gauge, a test bench, and a calibration fluid. You can find some Bosch VE manuals online , or you can order them from your local Bosch service center.
Before you start working on your Bosch VE pump, make sure you follow these safety precautions:
Wear protective gloves, goggles, and clothing to avoid contact with diesel fuel and calibration fluid.
Work in a well-ventilated area to avoid inhaling diesel fumes and vapors.
Keep away from open flames, sparks, and sources of heat to prevent fire and explosion.
Disconnect the battery and the fuel lines to prevent electric shock and fuel spillage.
Mark and label all the parts and components to ensure correct reassembly.
The following is a brief overview of the service and repair procedures for the Bosch VE pump. For more detailed information, refer to your Bosch VE pump manual.
Delivery Valve Service and Repair
The delivery valve is located on the top of the distributor head and has a sealing washer, a spring, a valve holder, and a valve. The delivery valve opens and closes to allow fuel to flow to the injector. If the delivery valve leaks or wears out, it may cause low fuel pressure, poor injection spray, reduced engine power, increased fuel consumption, and smoke emission. To service and repair the delivery valve, follow these steps:
Remove the delivery valve cap using a socket wrench.
Lift out the sealing washer, the spring, the valve holder, and the valve using a pair of pliers.
Clean all the parts with a clean cloth and inspect them for cracks, wear, corrosion, or damage. Replace any defective parts.
Lubricate the new sealing washer with clean diesel fuel and install it on the distributor head.
Install the spring, the valve holder, and the valve in the same order as they were removed.
Tighten the delivery valve cap to the specified torque using a torque wrench.
Plunger Service and Repair
The plunger is attached to the cam plate and rotates with it. The plunger has a helical groove that determines the injection timing and duration. The plunger moves back and forth in the plunger bore and pushes fuel through the delivery valve. If the plunger sticks or wears out, it may cause erratic injection timing, uneven fuel delivery, reduced engine performance, increased noise, and smoke emission. To service and repair the plunger, follow these steps:
Remove the distributor head from the pump body by removing the four bolts using a socket wrench.
Lift out the distributor head carefully and place it on a clean surface.
Remove the plunger from the distributor head by pulling it out with a pair of pliers.
Clean the plunger and the plunger bore with a clean cloth and inspect them for scratches, wear, scoring, or damage. Replace any defective parts.
Lubricate the new plunger with clean diesel fuel and insert it into the plunger bore. Make sure that the helical groove aligns with the notch on the distributor head.
Install the distributor head on the pump body by aligning the marks on both parts. Tighten the four bolts to the specified torque using a torque wrench.
Automatic Advance-Timing Device Service and Repair
The automatic advance-timing device is located on the front of the pump body and has a piston, a spring, a roller ring, and a housing. The automatic advance-timing device adjusts the injection timing according to the fuel-supply pump pressure. As the pressure increases, the piston moves the roller ring opposite to the drive shaft rotation, advancing the injection timing. If the automatic advance-timing device malfunctions or gets damaged, it may cause incorrect injection timing, poor engine performance, increased noise, and smoke emission. To service and repair the automatic advance-timing device, follow these steps:
Remove the automatic advance-timing device from the pump body by removing the three bolts using a socket wrench.
Lift out the automatic advance-timing device carefully and place it on a clean surface.
Remove the piston, the spring, and the roller ring from the housing by pulling them out with a pair of pliers.
Clean all the parts with a clean cloth and inspect them for cracks, wear, corrosion, or damage. Replace any defective parts.
Lubricate the new piston and spring with clean diesel fuel and insert them into the housing.
Install the roller ring on the piston by aligning the marks on both parts.
Install the automatic advance-timing device on the pump body by aligning the marks on both parts. Tighten the three bolts to the specified torque using a torque wrench.
Fuel-Supply Pump Service and Repair
The fuel-supply pump is located on the rear of the pump body and has a drive shaft, a rotor, a vane, a cover, and a pressure regulator. The fuel-supply pump is a positive displacement, vane-type pump that draws fuel from the tank and sends it to the distributor plunger and the automatic advance-timing device. If the fuel-supply pump is defective or dirty, it may cause low fuel pressure, insufficient fuel delivery, poor engine performance, increased noise, and smoke emission. To service and repair the fuel-supply pump, follow these steps:
Remove the fuel-supply pump from the pump body by removing the four bolts using a socket wrench.
Lift out the fuel-supply pump carefully and place it on a clean surface.
Remove the cover from the fuel-supply pump by removing the two screws using