005-012 Fuel Injection Pumps, In-Line

Table of Contents

General Information
Preparatory Steps
Remove
Install
Finishing Steps
Prime

General Information TOC

The Bosch® P7100 in-line fuel injection pump can be

found on the following engine application: SMALL | MEDIUM | LARGE

• 1991 high-horsepower automotive ratings Next

• 1994 automotive, all 6B ratings
• 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:

• Higher horsepower marine rating.

SMALL | MEDIUM | LARGE

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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

Previous Next

The Bosch® MW/RSV and MW/RQV in-line

fuel injection pump can be found on the
following engine application:

• 1996 and higher industrial emission

ratings.

SMALL | MEDIUM | LARGE

Previous Next

The Bosch® P3000/RQVK and P3000/RQV in-

line fuel injection pump can be found on the
following engine application:

• 1996 and higher high-horsepower

industrial emission rating.

SMALL | MEDIUM | LARGE

Previous Next

The Bosch® P3000/RSV In-line fuel injection pump

can be found on the following engine application: SMALL | MEDIUM | LARGE
can be found on the following engine application: Previous Next

• 1996 and higher high-horsepower industrial

emission ratings
• Marine.

The pressure relief valve arrangement 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 SMALL | MEDIUM | LARGE
pump or by cranking the engine.
Previous Next

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.

SMALL | MEDIUM | LARGE

Previous Next

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.

SMALL | MEDIUM | LARGE

 Previous Next

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.
SMALL | MEDIUM | LARGE
B Series industrial ratings and marine (after 1996)
engines use the Bosch® “A” in-line fuel injection
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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. SMALL | MEDIUM | LARGE

Previous Next

The fuel injection pump performs the three basic

functions of: SMALL | MEDIUM | LARGE

1. Metering the exact amount of fuel for each Previous Next

injection cycle
2. Producing the high fuel pressure required for
injection
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

Previous Next

Preparatory Steps TOC

WARNING

Batteries can emit explosive gases. To

reduce the possibility of personal injury,
always ventilate the compartment before
SMALL | MEDIUM | LARGE
servicing the batteries. To reduce the
possibility of arcing, remove the negative (-
) battery cable first and attach the negative Previous Next
(-) battery cable last.

• Disconnect the batteries.

 WARNING

Fuel is flammable. Keep all cigarettes, flames,

pilot lights, arching equipment, and switches
out of the work area and areas sharing
ventilation to reduce the possibility of severe SMALL | MEDIUM | LARGE
personal injury or death when working on the
fuel system.
Previous Next

WARNING

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.
• Remove the fuel supply lines. Refer
to Procedure 006-024.
• Remove the injector supply lines to the
pump. Refer to Procedure 006-051.
• Remove the control linkage. See the OEM
service manual.
• Remove the fuel shutoff valve. Refer
to Procedure 005-043.
• Remove the air fuel control air tube. Refer
to Procedure 006-001.
• Disconnect wastegate turbocharger
control line (if applicable).

Remove TOC
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.

SMALL | MEDIUM | LARGE

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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.

SMALL | MEDIUM | LARGE

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Remove the fuel injection pump mounting bracket, if

applicable. SMALL | MEDIUM | LARGE

Previous Next

CAUTION

Do not drop the nut and washer. Dropping the

nut and washer will result in the need to
SMALL | MEDIUM | LARGE
 Previous Next
Remove the gear cover access cap.

Remove the nut and washer from the fuel

injection pump shaft.

Use fuel pump gear puller, Part Number 3163381

or Part Number 3824469 with M8-1.25 x 50
capscrews, grade 8.8 or equivalent. Pull the fuel
injection pump drive gear loose from the shaft.

SMALL | MEDIUM | LARGE

Previous Next

Remove the four mounting nuts.

Remove the fuel injection pump.

SMALL | MEDIUM | LARGE

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Install TOC

Make certain that the engine has cylinder Number 1 at

top dead center. SMALL | MEDIUM | LARGE
 Previous Next

Remove the access plug.

SMALL | MEDIUM | LARGE

Previous Next

Remove the timing pin.

SMALL | MEDIUM | LARGE

Previous Next

If the timing tooth is not aligned with the timing pin

hole, rotate the fuel injection pump shaft until the SMALL | MEDIUM | LARGE
timing tooth aligns.
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Reverse the position of the timing pin so the
slot of the timing pin will fit over the timing
tooth in the pump.

Install and secure the timing pin with the

access plug.

SMALL | MEDIUM | LARGE

Previous Next

Use a 50/50 mixture of clean lubricating engine oil

and STP, or equivalent, to lubricate the gear cover SMALL | MEDIUM | LARGE
housing to make certain that the fuel injection pump
will slide into the gear cover housing easily.
Previous Next

WARNING

When using solvents, acids, or alkaline

materials for cleaning, follow the
manufacturer's recommendations for use.
SMALL | MEDIUM | LARGE
 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 notrequired. 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. SMALL | MEDIUM | LARGE

Previous Next

Slide the pump shaft through the drive gear and

position the pump flange onto the mounting
studs.

Push the pump forward until the mounting flange

and o-ring are properly fitted into the gear
housing bore.
SMALL | MEDIUM | LARGE
 Previous Next

CAUTION

Do not attempt to pull the pump flange into the

gear housing with the mounting nuts as
damage to housing can occur.
SMALL | MEDIUM | LARGE

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Install the mounting nuts.

Torque Value: 43 n.m [32 ft-lb]

Install the support bracket (if equipped).

Torque Value: 32 n.m [24 ft-lb]

SMALL | MEDIUM | LARGE

Previous Next

CAUTION

Do not drop the nut and washer. Dropping the

nut and washer will result in the need to
remove the front cover.
SMALL | MEDIUM | LARGE
To prevent damage to the timing pins,
do not exceed the torque value given. This
is not the final torque value for the retaining nut.

Disengage the engine timing pin.

SMALL | MEDIUM | LARGE

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CAUTION

The governor housing must be

prelubricated before engine operation.
Failure to do so can result in premature
governor wear. SMALL | MEDIUM | LARGE

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Remove the access plug.

Add the following quantity of clean

lubricating engine oil:

• RSV 450 mL [0.48 qt]

• RQV 750 mL [0.79 qt]
• RQVK 750 mL [0.79 qt]
Remove the fuel injection pump timing pin plug,
reverse the position of the timing pin, and install
the timing pin, plug, and sealing washer.

Torque Value: 27 n.m [20 ft-lb]

SMALL | MEDIUM | LARGE

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Tighten the fuel injection pump drive nut.

“A” Pump 85 n.m [63 ft-lb]

P3000 and P7100 195 n.m [144 ft-lb]
Nippondenso 123 n.m [91 ft-lb]
SMALL | MEDIUM | LARGE
Install the gear cover access cap hand-tight.
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Install the fuel injection pump mounting bracket

capscrews. SMALL | MEDIUM | LARGE

Tighten all capscrews by hand for proper alignment. Previous Next

Torque Value: 24 n.m [18 ft-lb]

Connect the external oil feed line at the inboard side

of the fuel injection pump (if applicable) and the main SMALL | MEDIUM | LARGE
oil rifle.
Previous Next
Connect the external oil feed line at the rear of the
pump or AFC latchout if applicable.
Finishing Steps TOC

• Connect wastegate turbocharger control line (if

applicable) SMALL | MEDIUM | LARGE
• Install the air fuel control air tube. Refer
to Procedure 006-001 Previous Next
• 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.

WARNING SMALL | MEDIUM | LARGE

Previous Next
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.

• Connect the batteries

Prime TOC
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 SMALL | MEDIUM | LARGE
fuel system.
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Refer to Procedure 006-051 Injector Supply Lines
(High 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 SMALL | MEDIUM | LARGE
on the fuel transfer pump or by cranking the
engine.
Previous Next

Injection Pumps - Venting

After priming the low 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 the fuel SMALL | MEDIUM | LARGE
l id l b i db f i
 Torque Value: 9 n.m [80 in-lb]

CAUTION

It is necessary to turn the keyswitch to the ON

position. Because the engine can start, be sure
to follow all safety precautions. Use the normal
engine starting procedure. SMALL | MEDIUM | LARGE

CAUTION Previous

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.

Air can also be vented through the fuel drain

manifold line by operating the starting motor.

Last Modified: 24-Apr-2006

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