9i,"
BOSCH
Contents
Function Dis-assembly Insp Inspec ecti tion on of Part Part Assembly
10
Calibration Pump Pump Moun Mounti ting ng Proc Proced edur ur
Function
Function Re oval oval of Inje Inject ctor or from from Engi Engine ne
ylin ylinde de Head Head
Func Functi tion onal al Test Test on Nozz Nozzle le Test Test Stan Stan Dis-assembly Insp Inspec ecti tion on of Part Part Assembly st ll ti
je to
in
14
th
id
Fig. 7: Re oval of Plunge Guid
Fi
r es si n
Cu
2.
Dis-assembly
Before attempting to dis-assemble ov th
in benc
th ar
re
it
clea
aper
ed in clea
kerosene coul
fuel injectio
fu
inseth
il
pump
ls parts, as Lor
also be used as an alternat
emov oldi (20) Re ov th is
cleaning
as th pr it
th
number in brackets hereon indicate
exploded view referenc
components as show
nu be fo individual
er Co ro
Pl cethe pu
in
itio in
dismantlin th ta
th (Fig 6)
to
emov th
li
in
delivery valv an valv
en th ot er
fr
le
lu
us holdin
ha
to loos
nu (18)
id
cu
retainin
ri
Fi
an
em
th
pi le seth forc plunge guid cup.
on th
ui
cu
th
Lift th lo er spri se (9), lu ge nd lu ge sp in (6 ut of th pu housing. ov contro slee lo it uppe spring se Fig. ). shthe lunger an keep it separately to preven damage
lace th
pu
position it holdin ut (1 er
dismantlin socket Fi
strong an
fi ture in
prig
rench, loosen delivery valv hile lo se in th nut,
steady pull on th
ench
in contac
arts
into th th in id
lu
body separately to
eing da aged by co in
fi ture in an in erte
in in
ld
ut (Fig an eliver lv hold delivery valv an valv body as unit
4)
lu
lu ge guid
ce th
leev
Ring
Caution: ev
in page 19
valv
Pl
Retainin
it
medium. Note Th
it
Cu
Fig. 8: Removing th
Contro
Sleeve
or ti hten th
deli
ry
ig
li
o os en i
o f D el i e r
al
H ol di n
vepl ng
rr
by
ry valv
in
(Fig
position by
eans of
shin
asse bl
it
Th
locating pi
he removed.
Nu
Fig. 10 Remova of PI.unger an
thro rr
an
Barrel Assembly
th
is held in
correspondin
ti as barrel separately to preven it from bein ta th ts
th
plunge an
barrel fo protection agains
possible damage.
Caution: lu
an
rrel
re
tc
ri
sh
ld
interchanged.
lu
ti an
lu
to
th
rr to th
seizure/stickiness
he su -a se
to
void
lu
to th
er to
se
of the element.
ly
given. Re ov contro
co tr
rack
rack stop scre
tr
le ve is
(27) Pull contro
In case bushings need replacement, usin
suitable to
th emov th
th second bushin
tt also in th
same manner
F ig .
e mo va l o f C on tr o
ac
to
c re w
Fig. 12,
r G
e C
13: Plunge
Spring
ri
is eplace pl ng
guid
cu
pl nger an tapp seatin 0.125 mm (0.005").
(7 if th surfac
Th cleara ce betw en guid
inde tation is
cu
th
or th
an th
ic
ly in le
El lu an rr 'm tc cannot be replaced individually
pu
housin
ha no effect on pump performance. Replacemen however, should be base
Replac
on mechanica judgement
plunge spring if
... Cracked/nicked ..
rr de
..
Surfac
Replac
co ting is da aged
spring seat if worn out/damaged.
Fig. 15: L o e r P lu ng e
(Element) it
constant us an
ear/scorin
of elemen plunger, th
If ther th
specifie
of th
as pe th
el
delivery
il affect th
is co sidera le
heli
lu ge ar ut thus nt articularl if th
mark is considerably abov th
obtained an this
S pr in g P la t
abrasive action of extremel
inut impurities in fu l, th affectin th tightnes le
alibration
an
region
uantit
en in
ear/sc ri
en pl ng
heli
cannot
erfo
in th
ance
egio
if specifie
abov alue
ar cannot be obtain d, th
elemen requires replacement. ccasionally, dark discolouration an seen on th ar el If th
surfac
deli er sh
pittin
lv seatin
mark
surfac
only discol uratio
an
th no
il If
is observed replace element.
ig. 16, Plunge
an
Barrel Assembly
led'
Fig.17, DeliveryValveHoldingNut
.4
eliver
amin
alve
deli er
thread
lv
or seat
.5
olding
olding
th
eati
alve
seatin
co po nd
lv
ld
.6
urface
rk as
ig
pressure
he
Insp ct
ffle ring fo
replac
barrel port
it
si
deli er
il
in
tt
Replace, if necessary.
seatin
(2 su face
of th
th re-used, th
iscolo atio
fter th t, thorou hl
ry th
fl
alve prin (19)
lv
amin
connecting threads.
ce sa y, cl an th
in le
eliver
cracked/nicked
If
ny
'.
ig
li
fo da ag
olde (2
surf ce to re
'clo
(Fig
fo damage to high-pressur
amin
ut (1
eplace if necessary.
eliver
Examin
Fig.19, DeliveryValveSprin
Fig.18 DeliveryHolder
al
li
delivery valv
dy that co lv
asse bl
ld 20:
DeliveryValve
21:
BaffleRing
us be replaced
must neve be replaced individually
ro heck th
cleara ce
ld replac
ev tw en cont ol
ac
it
If
bushings/control
rack If diametrica
is shings/contr le ithi ac
ushings. clearanc la
rack
ov co tr
rack
holdin
ir ly .2
by holdin
ld (0.0
inch).
imil ly
co tr
elem nt plun er st ti na y. Th ld
it in
co tr
.3
ar
osio
uncovered. If fo
cessive,
Fig. 23 Locating th
Fig. 22 Locating Pi
Elemen Barrel
se efor
asse blin
in clea
fuel an
grease from ne remove an
fuel injectio
them when
elemen
nd deli er
in petrol thoroughly Di
delive
valv
ump,
asse bl
pi
in clea
as
ll pa ts
et Pr tectiv
Th
le
is lo
into th
housin an in ig
valv should be
th
elemen plunge
filtered fu
t,
before
te
in
slot utside th barrel (indicated te th is it
th
te it li
assembly.
baffle ring
roun
assembly an
th
element. Instal delivery valv
delivery valv spring into pump housing.
Insert rubber '0' ring (11) over th Plac th
pu
housin
in (Fig. 22).
im
Afte both th bushings to to
.7
on an arbour pr ss pres in on
it
suit
ushing
ha
le
ti
in
ring (1
'0
insertio
of le
an
suitable guide. Afte
(0.7
pu
ne
pump housing.
to
th
stop scre Ex mine th barrel seat in th pump housing. atte pt to refinish th barrel seat bu re ov ther is an Th ig t, io
il
le
fixtur pum
in
uprigh
position
st th in
se
an
pu th
no dirt if
in in
dismantlin
Insert elem nt barre! into
Caution: Protection sleeve ha to be placed in betwee an an th
barrel to avoi
plunge top. Da ag to th seizure/stickiness of th
th
damage to th
plunge to
ca caus
pump Fig. 24 Aligning Mark
10
lu
nut.
efor
of vaseline
rings. Scre
ti ch te
th
it to .2 in
dism ntling fi ture in an in erte
contro rack into it bushing, an tc to th is isible th it
housing
plunge
uantit '0
si
in
sc
spring chamber. Plac pump housin
fa
in th
position Slid te it il
ly no in th
je ly
valv holdin smal
holder
pump housing.
Caution: replaced an
on deli er
ring sm ar
in to sp ci ie
Plac th
in is to
'0
delivery valv
Pum section)
it
bushings an
.2
Place
ldin to
.2
sea re me
reaming, thoroughly clea
lo
been inserted ream th
alue betwee
inch).
li
tl
to ensure that it is properly located. Th reafter, insert
it
th
sl
in th in
lock-wire.
to ck Ti
F ig . 2 5 P u
M ou nt e
ower th
o n T es t
e nc h
contro sleeve into th
pu
housin
an
ra
r ki n
edge of th in li
.4
ig
ark.
lu
lu
Instal uppe spring
ea an
th
id
up
ositio
lo er spring
plunge
in flange (vane) an
contro
plunge guid
into
he inspection
.1
plunge spring in pu
housing.
th
guid
certai
up do
that th
in
cu
ount th
fuel injectio
leev ar
um
spring pres ur
throug
to 50
or
drivin
akin
plunge flange (vane) en ages in th le
rt
ll guid
rod. Releas th
slot
il ro il
cup.
General Afte th
is ompletel
is no
asse bled he ra
lide freely
as re eren by
ov r.
on test benc
test injector
remainin
end.
it
he
is
Increase th
spee
of rotation throughout
clockwis
suitable
device pu
(Fig.25).
r-
as viewed from th
cale an
ontr
rack
contro rack to ards 'stop' an
is no furthe
movement Thereafter
ontrol rack to ards deli er
po itio
by 30
ig in in on th ontr rack he delivery uantity. If th valu is no obtained as pecified ar th position of ontrol
heck fo free
should
th
in (rpm). directio
ensure that ther
ra
pu
ovemen of ontrol rack he pu
holdin ov
re
er
re
in line
housing.
il
is co er
pu
ea to plunge an delivere
agains th
cu
indo
oc du
calibratio lide th
plunge guid
till pu
delivers specifie
ro
is
uantit
io
im
olding th in
that it indicates:
read fo calibration. V15
5.
Calibratio
Al Mica Bosc
Fuel Injectio
tested fo function
Pu ps ar thoroughly
mounting di ensions, delivery values
etc. before despatch Th os lo
calibratio
re is ls
es
houl hi
values specifie
alibration
ithout making an furthe ro ra
ench . e. ,
fo pump it
(refer
suitable is
am bo
id
plunge uide an an aligning ar on th pu housing. pu ps as embled it horter plunge guid ups,
havin
delive as sp cified used on th erase
th
pu
adjustment chec delivery at (i le io Stam
housin
th
tota thic ness of
near th
earlier stamping
poin er afte
ontr
.0
rave
unctio lv
itio te
in (rpm). Ther
200
ib fo
ef renc
io
purp se
sh ul
be no deli er
lu nl
tubing
is it
nion sl ev
servic
ny epaire
io
st tions,
is ta en fo testing,
th
in ir
th
sa
nut.
24 are
In dies
ific
dampen shoc av ilable befo
an
io
th
te
li
io
aves travelling throug
th
ltin
an
th
is
high-pressur iv
lv
nozzle valve.
re-set to
ld
limits
io Valve
Th
djusti
in variou
shim
fo cont ol rack
oi te
ar
availa le
thicknesses.
it holdin
Caution: ju in
it is
in in
fu it in
nd lo
inje io
to
snubbe
lo
th
iv
th
th Th
in
throug
assembly near
th
ific
th
sn bber
valv
sn bb
al
in
is
centre positio position ountin
bolt
uniforml to
cu
an
tighte in
djusti
scre
25.5° imin umps
re desi ne in
lu
is in
in
in
itio
imin
im
in
lo
li
in in id
in (bas
th th
fo 25.5° timing only
it id
cup)
nu firmly appropriately
Nm -3
ca 12
ut ti ht ni
torque
Nm
Nm
te le
al
sh ul
eplace
if
al
nd fe al
lv
broken
Replac part
ore)
in th
th foun
light source
ar
complete snubbe no
arketed.
valv
assembly as individual
Note Th um er in rack ts ereo in ic te th xplode ie referenc umbe fo indi idua comp nent as show in pa 21
1.
unctio
.1 um
sn bber valv ct nozzle va ve pe in
th
ngin
co
guid
us
usti
igh- ressur isch rg tu in ro st ress re he ozzl at mise
chamber. Th
compon nt (1), pressure (c rs ), (3), intermediate disc (6) an nozzle capnut Exploded Vi Nozz Hold r) 21
ro
aj
k- ro
Fig,
r e- t
Injectio
Nozzle
rr injector.
Th fu
injectio
ozzl
ar th
cl sed,
an
ydraul call
nozzle holder
pu lIe
re as an assembly
le
Operation
zz
th
ra
cleaning machine. zl
ss
su
el ve
th in
Cleaning
co ro
to
in
th
fuel
zz od
is ec ssar
fo lu rication ri th
reventin locked.
th
ozzl
valv fr
ra ec mi
ydra licall 13
Fig. 2: Nozzle
Tester
Tester 3.1
un th
inject
to nozzle tester usin pressu in th
ga ge of
shut of
in
testin
fi ture an
suitable high-pressur
ozzl tester
co nect
pipe Pu th
Fo ex
ut of circ it by scre in
lv knob (clock is
ple, if openin
gf/c -,
ol
th
slowly oper ting th
in
s-is conditio
at 240 kgf/cm fo an
le
is 260 seco ds
r.
directio ). le is
Toflus th nozzle about 10-12 stroke
pressu
pressu
perate th an le er of test fo at th fastes possible leve speed.
th
nozzle
id
it
ig
if
seco ds
ic
tnes
ll in
fall or formatio th
of oi le ti
is acceptable. Th
nozzle sh ul
re ea (chatt r)
and/or spra in
it
histling tone
ra
ll atomised fo th
To chec th openin in ircuit sc in clockwis th
direction)
nozzle ject
readin
th
su denl
pressure brin
th
pressure gaug lv i-
ff Slowly depres test
il
rops
th
nd th
hand leve unti
ress re
this stage,
ot
au
ow
shut
ff
ozzl test (4-6 stro
ll at
tern al
ised asthe nozzle
If th
openin
psi) an re-set.
Sl
ly
pressure
pressure lies betwee
270 kgf/crn" (3800
is satisf ct ry fo se
14
kgf/cm
(3600
thicknes of shim guid bush (sprin pattern/atomisatio
perate th
an
le er of
openin
ozzl test 20 kgf/crn
pressure recorded above.
ossi le sp ed th spra should no re ea
an
openin
tightness, spra pressure is lowe than
f/cr (3 si e-se th openin ress re to 260-270 kgf/crn? (3700 to 3800 si by ch ngin th
i) it is
pointer in pressure gaug indicate th
25
yo
in perate th
audibly.
If inject
injector openin
it direction)
hand le er at th fastes pe second). At this spee
pattern/atomisatio th
is
sati
th
pressure gauge reading. It indicate
cloc
to
unti th les than
et en nozzle ol er od an th cap) Repeat seal tightnes an spra tests
Absolute cleanlines is essentia during assembly/ dis-asse bl an testin of injectors. Th workin spac fr
fr
ir
ip
4.
Dis-assembly
ount th
injector in
nscrew th
benc
ic
or suitable fi ture
nozzle capnut usin P77
wrench. Lift th
nozzle of th
ocke
renc
th
needle sticks in th
nozzle in th
nozzle holder ta in
ar
il
is tuck in capnut du to excessiv carbon th
nozzle ou carefull
it
bras le ip
ro
rod, rd
ld
slide test
pressure surfac
pittin
arks et
betwee
th
should be free of cracks scratches,
that
ay caus an improper seal
nozzle holder an th lo
compressed air. Chec th
Removeother components from th in
Th
il
capnut to nozzle holder
fu
intermediate piece. ' cl e
thread
ry
fo an damage
nozzle holder body
il
Removecarbo
deposits from inne an
Examin fo cracks damage to thread lean an
Then soak th in difficul
dr
ld
it is piec
if broken
in
rf
spring coil determin nozzle body us an oi
cleane availabl
ollectin
th
in
re oved al traces of foreig
nozzle needle an thir
body al os of it
le ow weight
engage
body in filtered te
oil.
ertical, pull ou no zl (guide id
length
he
caus an
rectify.
groo
in nozzle cleaning kit.
if
Replace, if broken cracke
no zl
seatin
surface. Replace if necessary.
co pres ed ai into nozzle body
to re ov th
Afterhavin
oute surfaces an
nozzle in ultrasonic cleaning machine. Th
ir
lean th
as
re
le
formation, driv
lo
it by dipping
body clea
ultrasonic cleaning machine. in le
le If no zl
If no zl
part
aterial, rins olding th needle by on released th it
eplace intermediate di indentatio
at th
no zl
ro
ly
or excessivel
if foun eating en
ra ke
or
out.
or if
exceed
.1
6. Assembly If usin an
ne
nozzle re ov
wash th
th
preservative coatin
nozzle thoroughly in clea
petrol
assemble. Nozzle needle an sh
body ar
ld
'match assembled' Therefor
inte
th th
nozzles.
nozzl
body.
ldin
zzle
le length it
he
se
ti
ir
released th
it
as al th clea
lm st
im
l,
ll
th
it
id
nozzle should slid
down to
ig nozzle holder co ponent
thoroughly in
test oil.
.3
un tion zl
'nozzl
Te
ld
in
end' up ards
ldin
Insert shim
fi tu
it
(2), spring seat (3 F ig . 3 : T o a c hi ev e t ru e r un ni n (Par
spring. Asse bl
nozzle over th
nozzle capnut by an Tighte
th
or 94-109 torqu
No.9 686 03
of
. 3 mm, us
centerin
100)
intermediate disc Sc ew on th
an
centralise th
nozzle
nozzle capnut to 130-150 Nm (13-15 kgf·m s· t) to
it
it
le
sp
wrench th
inje
fr
fi
th
functional tests. Same as 3.1 te
Same as 3.2
nozzle have been us d, se th 275+10 kgf/cm fo inject
openin
pressure to
(3900 to 4050 psi). Re-setting pressur
it
zl
in
le is
260-270 kgf/cm2 (3700 to 3800 psi). te t: Same as 3.
io
Te
fo
lever speed.
r)
itio
in
ti
tt in
le Fig. 4: F o c he ck in g t h
(Part N o
16
00
H3
t ru e r un ni n
5 08 )
o f N oz zl e us
gaug
sleeve
Lowest test spee
is on
downward stroke/second.
Occasional/small non-repeatin ig ific nc
an sh
ld
ranges ar of no
ot be th
fast le er spee s, go
crit ri
re etitio
fo rejectio
is in icated by
ll
atomised spray.
Spray pattern/atomisation
homogeneous) fast leve
pe ds th
pr
is co
ac
nd fi el
atomised.
Engine ..
he
th
locating do el
..
th eari ozzl th
to
surfac
tain
hold r. Tighte
cl
is
th
is directly over th rall
th
cl
to th
he
in Ii
ti ht unti
surf ce
zzle holder bo y. Ti ht
la crew to torq approximatel 75 Ibs·ft
line of th
nuts ha
ha th
th
entr
th
th
id
fu
tube
100 Nm. (10 gf.m or an tighte high-pressur fuel
he
Ti ht
th
retainin
clam
nut,
manifold to 70 Nm. (7 kgf·
xt to th
xhaust
or 50 Ibs·ft).
True Runnin It
ta
th
injector care is take
th that th
Toachi ve tr ru in (par o. 9689034100) Further,
si
508), Note Failur
th
0.3 mm th centerin ha been used (Fig 3).
th true ru tr
to follow th
id breakage of nozzle
th
nozzle is centralised.
in
au th
abov
(p rt no
procedur
ca to
sleeve
02 H3
lead
F1
of
O25
spare R t l. l' ts " - ~ , - :'
~~
~ ~ ~ ,~ \
'\riI~!,rfl
Part No.
~~~t :.~/~
9411 035206
p h tf
9410035001 >4
Regulating sleeve rs
Plunge guid r s 10
cu
g p
2 F 9411304602
Spring ring
9411 030202 9411 033400
es
9411 034601
ef 9410035000
27
Screw
1 0 1 0 1 0 0,
mmthick
1 0 1 0 1 0
2,
mmthick
9411 030111
>29 >29/1*
k b
30 31
ashe fo 30
32
Inspection cover
33
Gasket fo 32
*No illustrated. Part subjec to wear an tear
18
0 3
~~'~;f~~;;
18
12
20
19 25 21
24
~~ ~)
22
.0
s:::;::;_
9430 21
302/
Fig.
24
no
no
eP
eP each
9431035132
Nozzle holde body Compensating washer
0.35 mm thic
2430 100601
0.
2430100602
thic
0.
as
mm thic
0.
thic
0.
thic
0 1
2430100606
1. mm thic
9 4 1 0 0 1 .2
thic
31
30
31
33
Spring seat
2434619008
Spring
2433124040
9431033320 >8
Nozzl for 1 B 1 57
34
57T
34
251 L 1 7 T
*Interchangeabl
with correspondin
AB
L 1
T 1
parts
Part subjec to wear an tear zzleis
ot supplied al ng
it
th
ozzl hold
Pleasestate orde number engraved on th
20
nozzle
nd henc isto
ordere
se arat ly
Washer 2320016-2 T4016D T4016F 2321267
9411 038401 U7 GU 76153
2F 10
rg
U7
1 0
2321325
'0
ring
tw
'0
ring
tw
delivery valv 1 0
2321338
nd holder
Pum housin
together with 18 24 27
1 0 2321355
Delivery valve holder
9411030000 A7
21
2321379
9411038505
Pointer elivery valv fo
1 0
Delivery valve spring
1 0
Contro rack assembly Regulating sleeve
G7
10
4 6 nspection cove
2321533 2322083 P7 2322164-1
1 0
BG 7678
2322662 A7 fo TM 822-6
22
51
9410035001 T5048A PF1
170/
T5048C 1 0 22310219-9
AD
1 B
15 ld or 9430031302 KB
24
no
R7 Shim
23210319 R7
28
SR 7629-3
23210322
R7
28 28
R7 SR 7629-6
23210325
A7
ic
in
Mica Bosc "l
r 2
ic
that of
osch ic
no
it
bu
in
ed
Pump housing. ontrol
osch an
ac Asse bl vice-versa
ha to be used on
Pu p, regulating sleeve should also be replaced
it
Test Specifications Test Equipmen Test Benc
Test Conditions
Mica/Bosch make
Inle pressure fo
O.S±O.l
calibration 68
Tes Injector
ig
ss
ip
34
00
Oil Temperatur
(EFEP218)
---------------------------
(oute diameter
wall thickness
length)
alibrati (Applicabl
al es
only
he
tested on
ica/ osch Test
ench
Pump
.~
~y
V1
500 30
9410035000
411
500
1 WV 1
500
Notes: (a Values give
in brackets ar
overchecking values
(b) Applicable only fo Mico an Bosc Test
di ension markin 'a': 6.
to be denote
enches
as
0.05mm
dimensio tappet in di ension he
is th
distance from th
DC position
pu
mounting
Se sketch alongside, This
us be maintained whil
ountin
th
pump
st
Caution: It is absolutely essentia to ensure maintenanc im
io
adherenc
th am
24
ot
th ti
cali ti lock
test th
of
nc in Fail
DC ll
will result in
im
si co tr
is sl
/ele
nt
lu
in ca
Measuremen
of BO
dimensio
.N
r.
~JJplication
Designation
Nozzle Cleaning/Testin Ultrasonic cleaning machine sn
Fo cleaning al nozzle Fo checking nozzle needle lift
/K 9686035001
9681033211 ei .0 ec
P1
lift
(t
ro
re
rc
lo
lly)
ew
e N er
2H 15 runnin
og
ef
of th
nozzle during injector
assembly
Nozzle Testin Nozzle Tester
Bosch EFEP60.......... Mica H-S/KDEP99 or H-Sj KDEP99A -A
F8
Fo connecting injector to
both sides) P6
t w
rh
9689033034
whil
H-S/KDEP 77
For loosening/tightening
9689033038
nozzle capnut
testin
r t
25
