Diesel Pump Oh

8/3/2019 Diesel Pump Oh

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Yes dieselheads, welcome to my friday evening activity: resealing abeautiful Bosch VE injection pump.

Note: This article does not explain how to replace the shaft bearingor how to set internal pressure. It is only a cleanup and resealing

guide.

The pump is in unknown condition, so let's go for a good rebuildwith disassembly, cleaning, and complete replacement of all seals.And its just as well, it was full of crud on the inside.

1

Here you see the startingpoint, a pump, seals kit with

the control lever seal anddriveshaft seal.

As usual, all components mustbe clean with strict cleanlinessmaintained throughout.Moreover, a good lubrication ofparts that push, contact, orslide is essential during thereassembly.

2We should not complain, arotary pump is worse! Here itis about an hour later.

I did not take pictures of thedisassembly, go in reversefrom what follows if you havedoubts for disassembly.Important settings to record:

1. Full load adjusting screw

See here.

2. Speed control lever

graduations See here.

3. Governor shaftadjustment screw See

here.
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3

Get started by doing thedistributor head hydraulics, it

will always be so de facto.Below are the differentcomponents of the deliveryvalve holder. bushing, spring,shim, needle, and new sealingwasher.

4

The copper sealing washer onthe delivery valve holder.

5

The finished distributor head.

That is done, so it is time toget to the serious mechanicals.
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6

Woohoo, its competelydisassembled! We see evenmy jeans clear through thebore.

7

Starting with the fuel feedpump, insert the stator ring.

8

Align 180 holes with the thepump housing taps (circled).


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9

Then the rotor and vanes.

10

First, the rotor.

11

then the vanes using aneedlenose plier.


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12

13

then the pressure plate.

14

and tightened down.


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15

Assemble the driveshaft.

16

with the governor drive gear.

17

and two rubber dampers.


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18

then the thrust plate.

19

and the woodruff key thatdrives the fuel feed pump.

20

Insert the shaft in the pumphousing.


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21

Here is the axial view.

22

In this radial view, you can seethe lozenge shaped hole forthe timing control.

23

Moving on to the next piece,the roller cage and timing pin.


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24The correct alignment for thetiming pin.

25

An axial view of the cagepositioned in the pumphousing.

26

Seen from the top.


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27

To understand how thesesystems interact, slide thetiming pin into the crossoverchamber so it protrudes intothe timing cylinder. The pincontrols the angular advanceof the roller cage.

28Now slide the actuator backout to install the timing piston.

This is the final position of theactuator.

29


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30Now we assemble the timingcontrol piston and pivot.

31This piston slides back andforth in the cylinder, causingthe timing pin to pivot theroller cage into advancedposition.

32

The piston is subject to twoforces during normal running.On the spring side, fuel pumpinlet pressure pushes it andthe chamber side, the fuelpressure inside the pumphousing pushes it the otherway. The balance of these twopressures set the timingadvance. When the inside

ousing pressure is high, thetiming is at maximumadvance.

The open end of the piston willclear the fuel pump inletgallery.


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33Insert the piston in thecylinder.

34

Now push the pin down thelozenge hole.

35

and lock with the pin.


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36

37

Clip the pin with the retainer.

38


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39Cover the cylinder with thenew seal.

40

With the cover screwed on.

41

Then on the other side, thetimer spring and coldstartadvance.


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42

43

There are no controls forelectrical coldstart on this car,so I put the usual cover on thecylinder.

44

Insert the cross coupling thatdrives the rest of the pump.


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45

46

Then the rollers. They areshown here in their cageoutside the pump.

Note the orientation of thewashers, which are shaped tothe inside curvature of theouter flange.

47


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48

49

Axial view of the rollersinstalled.

50

Insert the spring in the center.


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51

The spring in position.

52Put the cam disk in,completing the roller cage.

Timing is adjusted by theslight rotation of the rollercage relative to the camplate.

53

Note that the plunger drive pin(circled) aligns with thewoodruff key of the driveshaft.


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54

The cam lobes rolling on thecage cause the plunger toreciprocate and rotatesimultaneously, building thehigh pressure for injection.

55

Moving now to the distributorplunger.

The spill port (circled)regulates the volume ofinjected fuel. When the port isopen, pressure drops andinjecting stops.

56

The control collar (below),driven by the governor,adjusts the timing of the spillport.

When injecting, the plunger ispushed by the cam. Dependingon the position of thegovernor, the spill port isopened by the plunger stroke.

That is the control mechanismof the fuel injection.


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57Insert the distributor plungerin the distributor head.

58

Then the return springs.

59


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60

The spacer of the plunger end.

61

62

Insert the entire distributorhead assembly into the pump,but don't tighten it down justyet.


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63

The radial view.

64

We will now go the governortension lever and supportsprings.

65

Support springs go in theseholes. This part can be a bit ofa challenge getting the springspositioned.


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66

67

The tension lever pivots onthree sided bolt-hinges. Imodified an old 13mm socketto fit the triangular bolts.

68

Insertion of these bolts withnew aluminum washers.


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69Now we are installing the leverassembly from the top.

70

To do this, remove the

distributor head (which you didnot bolt down) and positionthe lever assembly so it lookslike this.

Notice on the plunger shaft thespill port (green), thedistributing slit (red), and fourintake slits (green) extendinginto the high pressurechamber. The plunger isgalleried to facilitate all this.

71

The hydraulic manifold readyto assemble with the returnsprings.


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72

Now we are ready to install the

head assembly and screw it in.This may be a bit of achallenge since the springstend to fall out, so have somepatience here.

73

The top view.

74

Turning now to the centrifugalgovernor, here are all theparts.


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75

Assemble the flyweights.

76

Put that assembly into therotor.

77


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78

Replace the governor sleeve.Note the calibration hole thatmodulates initial injectionaccording to load.

79

Insert the shaft through therotor.

80

The governor adjustmentscrew.


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81Washers between the rotorand housing.

82

83

Install the rotor assembly.


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84

The adjustment of this shaft isimportant, because it

modulates initial injectionaccording to load (along withvacuum, if so equipped). Thisis why it is a good idea tomark its position atdisassembly.

85

Use a hex key to screw in the

shaft to the same position itwas before disassembly. Usetwo wrenches at the same totighten the time jam nut sothe shaft is locked.

Now the pump housing iscomplete, only needing thepump cover and the fuelpressure regulation valve.

86

On the cover, drive out the oldcontrol shaft bushing.


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87

88

Insert the new bushing fromthe inside.

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Use an old bolt and largewashers to clamp the bushingdown flush.


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90

91

Put in the control shaft andyoke.

The yoke assembly holds threesprings, the governor spring,the partial-load spring and theidle damper spring.

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Close up of the governorlinkage. Retract the rod so theflat section in the rod (green)slips into the narrow slot in thelever (red).


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93

Assemble the speed controllever with its return spring andnew seal.

94

Here you see the idle adjustingscrew on the top of thepicture, and the maximumspeed screw at he bottom.

This is one place where youneed to identify the lever'ssetting at disassembly. Adjustit to the same graduation.

95

The regulating valve sets theproper fuel pressure for thetiming advance and fuel feedfor the distributor plunger.

Install it now with new seals.


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96

97

The fuel shutoff solenoid.

98

Notice that immediately abovethe solenoid is the full loadadjusting screw. You mayprefer to mark the setting ofthis screw before disassembly.


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99

Last piece, the driveshaft seal.

100

101

You have done it! Not as hardas you thought it would be.

All that is needed now is tomount the pump!

Popup by Joao Rodrigues Script modified: 2011/02/18

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Diesel Pump Oh

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