Fuel Injection Pumps, In-Line (005-012)
Contents
1. Metering the exact amount of fuel for each injection cycle 2 Producing the high fuel pressure required for injection file C DOCUME I au172 LOCALS 1 Temp 554K Y C8C htm Page 6 of 19 Manual Venting Controlled Venting 8 AG 2 2 2 i Soy Han foo Gor an i L i SMALL MEDIUM LARGE Previous Next Nippondenso EP 9 with ASV Governor pe SMALL MEDIUM LARGE 10 31 2008 Page 7 of 19 3 Delivering the high pressure metered fuel to each cylinder at the precise time Individual plungers are used in the pumps to develop and distribute the high pressure required for injection A worn or damaged plunger in the pump will affect only one cylinder SMALL MEDIUM LARGE Preparatory Steps TOC A WARNING A Batteries can emit explosive gases To reduce the possibility of personal injury always ventilate the compartment before servicing the batteries To reduce the possibility of arcing remove the negative battery cable first and attach the negative battery cable last SMALL MEDIUM LARGE e Disconnect the batteries file C DOCUME I au172 LOCALS 1 Temp 554K Y C8C htm 10 31 2008 Page 8 of 19 A WARNING A Fuel is flammable Keep all cigarettes flames pilot lights arching equipment and switches out of the work area yo and areas sharing ventilation to reduce the possibility of severe personal injury or death when working on the fuel aiia system SMA2. the position of the timing pin and install the timing pin plug and sealing washer Torque 20 ft Value Ib SMALL MEDIUM LARGE Summary 29 Tighten the fuel injection pump drive nut file C DOCUME I au172 LOCALS 1 Temp 554K Y C8C htm 10 31 2008 Page 16 of 19 A Pump 85 n m 63 ft lb P3000 and P7100 195 n m 144 ft lb ale Nippondenso 123 n m 91 ft lb pp oS Install the gear cover access cap hand tight Summary 31 Install the fuel injection pump mounting bracket i sa ca SCrews Ne kakak a W a Ta T 4 j EEEE A ae et ES eg ei Vek etl Tighten all capscrews by hand for proper alignment Torque 24 18 ft Value n m Ib SMALL MEDIUM LARGE Summary 33 Connect the external oil feed line at the inboard side of the fuel injection pump if applicable and the main oil rifle Connect the external oil feed line at the rear of the pump or AFC latchout if applicable SMALL MEDIUM LARGE file C DOCUME I au172 LOCALS 1 Temp 554K Y C8C htm 10 31 2008 Finishing Steps Connect wastegate turbocharger control line if applicable Install the air fuel control air tube Refer to Procedure 006 001 Install the fuel shutoff valve Refer to Procedure 005 043 Install the control linkage See the OEM service manual Install the injector supply lines to the pump Refer to Procedure 006 051 Install the fuel supply lines Refer to Procedure 006 024 A WARNIN
3. 2 ft lb Install retaining nut and washer Torque 10 to 15 Nem 7 to 11 ft lb AD Disengage engine timing pin eee eee Remove access plug and add lubricating Stepblock ESE Remove access plug and add wbricating CA Remove fuel pump timing pin plug and Stepblock A Pump 85 Nem 63 ft lb In line Tighten fuel pump drive nut Pumps P3000 and P7100 195 Nem 144 ft lb and Nippondenso Pump 123 Nem 91 ft lb Install gear cover access cap Hand tighten Install fuel injection pump mountin Stepblock J pump g Be erene e O Tighten capscrews by hand Torque 24 Nem 18 ft lb file C DOCUME I au172 LOCALS 1 Temp 554K Y C8C htm 10 31 2008 Page 3 of 19 Stepbiock Connect external oil fed lines Connect wastegate turbocharger control line if applicable and install air fuel control air tube Procedure 006 001 Install fuel shutoff valve Procedure 005 043 and control linkage see OEM service manual Install injector supply lines to pump Procedure 006 051 and fuel supply S hoo Ponp venna Procedure 006 024 Vent air and fuel from eston Pures veres aua EP 9 Energize fuel solenoid valve on Lucas and Lucas CAV fuel injection pumps CAV pump before venting Loosen vent screw and operate priming lever until injection pump primed Tighten vent screw Torque 9 Nem 80 in lb General Information TOC The Bosch P7100 in line fuel injection pump ca
4. G A Batteries can emit explosive gases To reduce the possibility of personal injury always ventilate the compartment before servicing the batteries To reduce the possibility of arcing remove the negative battery cable first and attach the negative battery cable last e Connect the batteries e Operate the engine and check for leaks Prime Replacing the fuel supply lines fuel filters fuel injection pump high pressure fuel lines and injectors will let air enter into the fuel system Follow the specified procedure to bleed the air from the system Refer to Procedure 006 015 Fuel Filter Spin On for proper venting of the low pressure side of the fuel system file C DOCUME I au172 LOCALS 1 Temp 554K Y C8C htm Page 17 of 19 TOC SMALL MEDIUM LARGE Summary 36 Summary 37 SMALL MEDIUM LARGE F j 10 31 2008 Page 18 of 19 Refer to Procedure 006 051 Injector Supply Lines High SMALL MEDIUM LARGE Pressure for venting of the high pressure side of the fuel system The MW A and P fuel injection pumps equipped with the engine side fuel drain arrangement create a self bleeding system for air introduced during replacement of the supply side components For faster air purge small amounts of air can be bled from the pump by operating the hand primer on the fuel transfer pump or by cranking the engine Injection Pumps Venting Litas CAV p i a a Sen After priming the lo
5. LL MEDIUM LARGE A WARNING A some state and federal agencies have determined that used engine oil can be carcinogenic and cause reproductive toxicity Avoid inhalation of vapors ingestion and prolonged contact with used engine oil If not reused dispose of in accordance with local environmental regulations Clean any debris from the fuel injection pump 4 Remove the fuel supply lines Refer to Procedure 006 024 e Remove the injector supply lines to the pump Refer to Procedure 006 051 e Remove the control linkage See the OEM service manual e Remove the fuel shutoff valve Refer to Procedure 005 043 e Remove the air fuel control air tube Refer to Procedure 006 001 Disconnect wastegate turbocharger control line if applicable Remove Disconnect the external oil feed line at the inboard side of the fuel injection pump if applicable and the main oil rifle Disconnect the external oil feed line at the rear of the pump or AFC latchout if applicable D 4 f E F Li j a i f a N SMALL MEDIUM LARGE file C DOCUME I au172 LOCALS 1 Temp 554K Y C8C htm 10 31 2008 Page 9 of 19 Locate top dead center for cylinder Number 1 Push the top dead center pin into the hole in the camshaft gear while Slowly barring the engine NOTE Be certain to disengage the timing pin after locating top dead center Min i oe ie e Remove the fuel injection pump mounting bracket if eane applica
6. Page 1 of 19 Fuel Injection Pumps In Line 005 012 Table of Contents Summary General Information Preparatory Steps Remove Install Finishing Steps Prime Summary umop Remove fuel supply lines Procedure 006 024 and injector ont lines to Procedure 006 051 Remove control linkage see OEM Stepblock service manual and fuel shutoff valve Procedure 005 043 Remove air fuel control air tube Procedure 006 001 and disconnect wastegate turbocharger control line if applicable Stepblock Connect batteries operate engine and TEES emne na for leaks Locate cylinder Number 1 top dead Stepblock y p e Disengage timing pin a ee Remove gear cover access cap and nut Stepblock Pull the fuel injection pump drive gear Part Number 3163381 or Part Number file C DOCUME I au172 LOCALS 1 Temp 554K Y C8C htm 10 31 2008 Page 2 of 19 loose from shaft 3824469 with M8 1 25 x 50 grade 8 8 or equivalent Stepblock Remove four mounting nuts and fuel oump center eT A ImINg DPIN If timing tooth not aligned with hole rotate fuel injection pump shaft until tooth aligned olug Stepblock Stepblock Lubricate gear cover housing and Use 50 50 mixture of clean engine oil Side pump shattthrough arive geer S O O Push pump until flange and o ring Stepblock block Stepblock Laeerer oroperly fit into housing bore Install mounting nuts Torque 43 Nem 3
7. ble FAN S ie TA net eee A CAUTION A Do not drop the nut and washer Dropping the nut and washer will result in the need to remove the front cover Remove the gear cover access cap i perea Ter LARGE i the nut and washer from the fuel injection pump file C DOCUME I au172 LOCALS 1 Temp 554K Y C8C htm 10 31 2008 Page 10 of 19 Use fuel pump gear puller Part Number 3163381 or Part Ho Na Number 3824469 with M8 1 25 x 50 capscrews grade 8 8 i N or equivalent Pull the fuel injection pump drive gear loose 2 from the shaft Sa a a ie A ini F a Remove the four mounting nuts jea oh iv ion Remove the fuel injection pump oe ee bai f F L t SMALL MEDIUM LARGE Install Make certain that the engine has cylinder Number 1 at top dead center file C DOCUME I au172 LOCALS 1 Temp 554K Y C8C htm 10 31 2008 Page 11 of 19 Remove the access plug Remove the timing pin lf the timing tooth is not aligned with the timing pin hole rotate the fuel injection pump shaft until the timing tooth aligns Reverse the position of the timing pin so the slot of the timing pin will fit over the timing tooth in the pump file C DOCUME I au172 LOCALS 1 Temp 554K Y C8C htm 10 31 2008 Page 12 of 19 Install and secure the timing pin with the access plug Summary 19 Use a 50 50 mixture of clean lubricating engine oil and STP or equivalent to lubricate
8. ement on the Bosch P7100 fuel injection pump in the supply side of the fuel circuit creates a self bleeding system for air introduced during replacement of the supply side components Small amounts of air can be bled from the pump by operating the hand primer on the fuel transfer pump or by cranking the engine The Bosch P7100 in line fuel injection pump has a jump over tube to route return fuel and entrapped air from the pressure relief valve directly to the supply tank ee SO a PETT ma SMALL MEDIUM LARGE The Nippondenso EP 9 in line fuel injection pumps will require additional venting prior to initial start up pump replacement or if engine fuel runs out file C DOCUME I au172 LOCALS 1 Temp 554K Y C8C htm 10 31 2008 Fuel Injection Pump In Line Type Beginning in 1991 the B Series engine used the Bosch P7100 in line fuel injection pump on higher horsepower automotive ratings In 1994 all automotive 6B Series engines used the Bosch P 7100 in line fuel injection pump B Series industrial ratings and marine after 1996 engines use the Bosch A in line fuel injection pumps The B Series engine also uses the Nippondenso EP 9 with RSV governor on 1996 or earlier engines with a 250 and 300 horsepower marine rating Refer to the B Series Marine Operation and Maintenance Manual Bulletin 3810466 for additional information The fuel injection pump performs the three basic functions of 1
9. h the pump forward until the mounting flange and o ring are properly fitted into the gear housing bore file C DOCUME I au172 LOCALS 1 Temp 554K Y C8C htm 10 31 2008 Page 14 of 19 Mage PS ar 4 ug Z PEER ci i Er PIT oe a 4 A CAUTION A mee Do not attempt to pull the pump flange into the gear housing with the mounting nuts as damage to housing can occur Install the mounting nuts Torque 43 32 ft Value n m Ib Install the support bracket if equipped Torque 32 24 ft Value n m lb A CAUTION A Do not drop the nut and washer Dropping the nut and washer will result in the need to remove the front cover IpSnuhb Install the retaining nut and washer SMALL MEDIUM LARGE Torque 1010 15 89 to 133 Value n m in lb To prevent damage to the timing pins do not exceed the torque value given This is not the final torque value for Summary 25 the retaining nut Disengage the engine timing pin file C DOCUME I au172 LOCALS 1 Temp 554K Y C8C htm 10 31 2008 Page 15 of 19 Oil Fill A CAUTION A The governor housing must be prelubricated before engine operation Failure to do so can result in premature governor wear SMALL MEDIUM LARGE Remove the access plug Add the following quantity of clean lubricating engine oil Previous e RSV 450 mL 0 48 qt e RQV 750 mL 0 79 qt e RQVK 750 mL 0 79 at Remove the fuel injection pump timing pin plug reverse
10. n be found on the following engine application e 1991 high horsepower automotive ratings e 1994 automotive all 6B ratings e 1996 emissionized high horsepower industrial ratings The Nippondenso EP 9 in line fuel injection pump with the RSV governor can be found on the following engine application e Higher horsepower marine rating SMALL MEDIUM LARGE file C DOCUME I au172 LOCALS 1 Temp 554K Y C8C htm 10 31 2008 Page 4 of 19 The Bosch A RSV in line fuel injection pump can be found on the following engine application Pre 1996 noncommissioned industrial ratings 1996 industrial emission ratings Marine Gensets SMALL MEDIUM LARGE The Bosch MW RSV and MW RQYV in line fuel injection pump can be found on the following engine application e 1996 and higher industrial emission ratings SMALL MEDIUM LARGE The Bosch P3000 RQVK and P3000 RQV in line fuel injection pump can be found on the following engine application e 1996 and higher high horsepower industrial emission rating SMALL MEDIUM LARGE file C DOCUME I au172 LOCALS 1 Temp 554K Y C8C htm 10 31 2008 Page 5 of 19 The Bosch P3000 RSV In line fuel injection pump can be found on the following engine application e 1996 and higher high horsepower industrial emission flies Co Lif ratings EE Tuae p e Marine gE i 7 ne a i st z b L b at id aia SMALL MEDIUM LARGE The pressure relief valve arrang
11. the gear cover housing to make certain that the fuel injection pump will slide into the gear cover housing easily DAA i A WARNING A When using solvents acids or alkaline materials for cleaning follow the manufacturer s recommendations for use Wear goggles and protective clothing to avoid personal injury A WARNING A Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause bodily injury file C DOCUME I au172 LOCALS 1 Temp 554K Y C8C htm 10 31 2008 Page 13 of 19 Ere 2 The fuel injection pump drive gear inside diameter and the shaft outside diameter must be clean and dry before installing the gear Failure to do so can result in slipped timing NOTE Before installing the fuel pump drive gear clean the injection pump shaft and gear tapers with residue free cleaner Part Number 3824510 by spraying into the gap between the shaft and the gear Dry with compressed air NOTE The in line fuel injection pump driveshaft has a provision for a Woodruff key however it is not required Timing mark alignment is not required for the in line drive gear NOTE Make certain that the engine has cylinder Number 1 at top dead center Make certain that the o ring seals for the fill orifice and pilot are correctly installed and are not damaged Install new pilot o ring Slide the pump shaft through the drive gear and position the pump flange onto the mounting studs Pus
12. w pressure fuel lines see Procedure 006 015 Fuel Filter Spin On Type air fuel can be vented from the illustrated vent locations on the Nippondenso EP 9 and the Lucas CAV fuel injection pumps The Lucas CAV fuel injection pump requires that 9 i the fuel solenoid valve be energized before venting Ml E e SMALL MEDIUM LARGE Loosen the vent screw and operate the priming lever on the fuel transfer pump until the fuel injection pump is primed Summary 39 Torque i Value i Summary 40 Summary 41 Tighten the vent screw A CAUTION A It is necessary to turn the keyswitch to the ON position Because the engine can start be sure to follow all safety orecautions Use the normal engine starting procedure file C DOCUME I au172 LOCALS 1 Temp 554K Y C8C htm 10 31 2008 Page 19 of 19 SMALL MEDIUM LARGE A CAUTION A When using the starting motor to vent the system do not engage it for more than 30 seconds or starter damage will occur Wait 2 minutes before starting the engine again Summary 42 Air can also be vented through the fuel drain manifold line by operating the starting motor Last Modified 24 Apr 2006 Feedback Help Copyright 2006 Cummins Inc All rights reserved file C DOCUME I au172 LOCALS 1 Temp 554K Y C8C htm 10 31 2008
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