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Checking timing on bosch ve type injection pump

I have a 1991 d350 with the cummins engine, i have the engine at TDC, but am installing a used injection pump. i am wanting to know how to check that the pump is set to TDC before i install it

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  • Dodge Master
  • 22,095 Answers

Put some fuel in it then turn the pu,p ovedr till you see fuel spit from no1 ,also if this is a rotary pump you remove the little cover on the side of the pump and look at the letters ,i cannot for the life of me remember what they are and all my notes from the ford training centre in daventry got eaten by mivce when i moved to spain ,you could ask in your local bosch agent /repair centre they would know

Posted on Dec 28, 2013

  • 1 more comment 
  • bee39520
    bee39520 Dec 28, 2013

    ok thanks ill do that.. im just learning about diesels since i bought this one .....

  • Colin Stickland
    Colin Stickland Dec 29, 2013

    nothing wrong with a diesel ,another tip if your in or going to a extremely cold area and temperatures drop below -10c the add a couple of litres of petrol to a tank of diesel to stop it waxing up ,as for the timing i done a course at ford daventry in the uk on cummins diesels many years ago but they had inline pumps not rotary .some older models had a keyway on the pump shaft and the timing mark on the gear wheel ,if in doubt use the spill timing method then look for a mark somewhere ,as i stated iam old and well past my sell by date but if your stuck then reply to post one head and one old decrepit old timer are better than none .

  • bee39520
    bee39520 Mar 21, 2014

    finally went and got new pump installed it like you said , tdc on engine and pump at #1. problem now is that its hard to start and pours white smoke... how do i set the timing on it ? it is the rotary pump, bled all the lines ,and have pure fuel coming out. the smoke smells like raw diesel

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Posted on Jan 02, 2017

ilragatzzo78
  • 241 Answers

SOURCE: no fuel coming from fuel injection pump,bosch inline 5 cylinder

IT SOUND LIKE A BAD FUEL PUMP TO ME.
TRY SCANNING THE VEHICLE FOR ANY CODE.
IF THERE ARE CODES POST THEM HERE AND I WILL LOOK THEM UP FOR YOU

Posted on May 28, 2008

  • 10 Answers

SOURCE: timing zx2 escort TDC ?

The cams have a notch in the back of them (facing driver's side) in which fits a flat piece of steel to lock the cams in place. The notches are not exactly centered on the camshaft, meaning that it's impossible to set them 180 degrees out, because then the flat piece of steel that is supposed to be inserted to lock the cams in place simply won't fit because the top of the cylinder head will get in the way. I highly recommend getting a Hayne's or Chiltons manual if you don't already have one. It should explain this process under the Timing Belt Replacement instructions. The cam lock tool (that flat piece of steel) can be purchased at ZXturner.com:
http://zxtuner.com/product.sc?categoryId=23&productId=191

Posted on Jun 29, 2008

MrScary66613
  • 1990 Answers

SOURCE: TDC in Haynes Manual- Isuzu Rodeo TF 1991

No. 4 to Top Dead Center is Correct.

Posted on Jan 03, 2009

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A Isuzu NPR 4hf1 rotary pump timing marks set


Hi. If it has a rotary pump, the pump needs to be installed with the crank at 49 deg BTDC on the compression stroke cyl 1. Mark dot gear on pump with white paint. Line up dot gear on pump with line on pump bracket and install. Remove PRM sensor from bell housing and check if line on pump gear is still lined up with line on pump bracket.

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I changed engine blocks on my log skidder, it has a 5.9 cummins. Used the same injector pump and new injectors, the engine starts and runs idle good but has no power.tried timing it a different way 100...


easy, no year stated nor injection system. (old pump, mpi or direct injected)
my guess is the pump has issues or the fuel feed to it is restricted.
id buy the FSM that matches that engine,and real the injection chapters, and all tests stated there.
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Hi, I need some help please! I have a peugeot 406 2.1 td p reg. I've had to put a 1.9 bosh pump on it to bipass the imobiliser. does any one know what order the injection pipes go in. cheers ale


Hi Alex, The firing order is 1-3-4-2. When fitting the injector pump I hope you noticed the match marks for timing. When fitted and aligned the engine will be at TDC firing on one. To identify # 1 on the pump, connect the fuel supply and bleed air from the system and rotate the engine one and three quarter revolutions by hand, having someone watch which outlet ejects fuel when passing TDC completing the second rotation. That will indicate number one piston. Follow the firing order for the remaining three. Regards John

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P0216 DTC - Injection Timing Control Circuit Malfunction and this means the diesel fuel injection pump has a timing failure. This could be that the injection pump timing needs adjusted OR the failure is internal to the injection pump and therefore non-adjustable.

NOTE: If your vehicle is a Dodge Ram with Cummins engine then be aware that fuel delivery problems frequently cause this code. Prolonged fuel delivery problems can cause injection pump failure!

Symptoms of a P0216 DTC may include:
Low power
Crank, but no start
Hard start
Displays an intermittent stumble or miss
Engine may start and then stall
Engine may appear to drive fine but surge at idle


The most frequent cause of this code is a bad injection pump due to poor fuel delivery. Fuel delivery problems could be:
A plugged diesel fuel filter
An in-tank blockage
Air in the fuel due to a cracked in-tank fuel ine above the fuel level
Bad transfer (lift) pump
Injection pump out of time


Possible Solutions: First, simply check if your injection pump timing is adjustable. If so, check the timing and adjust if necessary.

If you think that you may have a fuel delivery problem, then check the lift pump operation. On Dodge Ram with the Cummins engine, the lift pump should produce about 45 oz of diesel in 25 seconds of operation. This can be performed by disconnecting the fuel hose from the injection pump and pumping the fuel into an approved container. Bump the engine over but do not start it. Then the lift pump will operate for 25 seconds. If the fuel is aerated, then check/repair fuel line and recheck.

With the fuel hose connected the fuel pressure should be 10psi. If the fuel delivery tests fail, replace the diesel fuel filter and recheck.

If it still fails then verify there are no restrictions in the fuel tank

Then replace the lift (transfer) pump. IT SHOULD BE NOTED that if this code surfaced after a routine fuel filter replacement or if you have any of the above symptoms after routine fuel filter replacement, then suspect the fuel transfer pump. This occurs because even a weak transfer pump can still provide enough fuel for the engine to run. But when the fuel system\'s prime is lost due to fuel filter replacement, it may not restart again without fixing the fuel delivery problem.

If you found your injection pump to be bad, the lift pump should be checked for operation to protect the new injection pump. This is because weak or low output from lift pump are common cause of injection pump failure. There are some aftermarket kits that can be purchased to warn the operator when the fuel pressure/volume drops to level that could damage the injection pump.

Hope this helps (remember to rating this free answer and leave a testimonial comments).

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I NEED BALAST RESISTOR FOR ALTERNATOR. TRUCK IS A 1991 DODGE D350 WITH A 5.9L CUMMINS TURBO DIESEL. CAN I GET RESISTOR SEPARATELY FOR ALTERNATOR?


Never known a ballast resistor in a altenator but their is a zena diode ,this is not to say their isnt one on a american vehicle but iam in europe so never seen one but i would imagine the part would be available from a local bosch repair agent as they have everything else in our local agency

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Timing marks trooper 1985 mod dlx turbo diesel


Refer to Figures 1,2,3,4 when performing 17-step timing procedure for 1981-1985 Diesel Engines.

Fig 1. Injection pump and camshaft alignment marks - Diesel engine.

archaeology_66.jpg


Fig 2. Removing the timing belt holder - Diesel engine.

archaeology_67.jpg

Fig 3. Injection pump alignment marks - Diesel engine.

archaeology_68.jpg

Fig 4. Tensioiner Pulley Bolt Sequence - Diesel engine.

archaeology_69.jpg

Procedure - Timing Belt replacement.

1. Disconnect the negative battery cable. Drain the cooling system.

CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

2. Remove the timing belt cover. Remove the injection pump sprocket flange.

3. Using a prybar, remove the tension spring from the timing belt tensioner.

When removing the tension spring, avoid using excessive force for the spring may become distorted.

4. Remove the tensioner pulley bolt and the pulley.

5. Remove the timing belt and discard it.

To install:

6. Rotate the crankshaft to bring the No. 1 piston to TDC of the compression stroke.

7. Align the timing marks on the injection pump sprocket with the camshaft sprocket; the marks must be facing each other.

8. Using a new timing belt, install it in the following sequence: crankshaft sprocket, camshaft sprocket and the injection pump sprocket; the slack must be between the injection pump and camshaft sprockets.

9. Install the tension center and the tension pulley so the end of the tension center is fitted against both pins on the timing pulley housing.

10. Hand tighten the nut so the tension pulley can be rotated freely.

11. Install the tension spring and semi-tighten the pulley nut to 22-36 ft. lbs. (30-48 Nm).

12. Rotate the crankshaft 2 full turns clockwise to seat the belt and further turn the crankshaft 90° beyond TDC to settle the injection pump.

13. Loosen the tension pulley nut to take up the timing belt slack. Tighten the tension pulley nut to 79-94 ft. lbs. (108-128 Nm).

14. Install the injection pump sprocket flange; the hole in the outer circumference of the flange should be aligned with the triangular timing mark on the injection pump sprocket.

15. Rotate the crankshaft 2 full turns clockwise to bring the No. 1 piston to TDC of the compression stroke. Make sure the triangular timing mark on the timing sprocket is aligned with the hole in the flange, then, measure the timing belt tension; it should be 33-55 lbs.

16. Install the timing belt cover.

17. Connect the negative battery cable.

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1 Answer

Hi, noticed a post of yours rear cambelt replacement on an a4 1.9 tdi ajm year 2000. Would be very grateful for any instructions. The car is stripped down ready for cambelt removing. Stuck on lining up...


Hi, I have pasted instructions below from autozone.com. The instructions call for the use of special tools. You can improvise with alternate tools, but please make sure your timing is right before closing the cover. Please let me know if you have questions, and thanks for using FixYa.

1.9L Diesel Engine
Some special tools are required to perform this procedure properly. A flat bar, VW tool 2065A is used to secure the camshaft in position. A pin, VW tool 2064 is used to fix the pump position while the timing belt is removed. The camshaft and pump work against spring pressure and will move out of position when the timing belt is removed. It is not difficult to find substitutes but do not remove the timing belt without these tools.

WARNING Do not turn the engine or camshaft with the timing belt removed. The pistons will contact the valves and cause internal engine damage.
  1. Disconnect the negative battery cable and remove the accessory drive belts, crankshaft pulley and the timing belt cover(s). Remove the camshaft cover and rubber plug at the back end of the camshaft.
  2. Temporarily reinstall the crankshaft pulley bolt and turn the crankshaft to Top Dead Center (TDC) of No. 1 piston. The mark on the camshaft sprocket should be aligned with the mark on the inner timing belt cover or the edge of the cylinder head.
  3. With the engine at TDC, insert the bar into the slot at the back of the camshaft. The bar rests on the cylinder head to will hold the camshaft in position.
  4. Insert the pin into the injection pump drive sprocket to hold the pump in position.
  5. Loosen the locknut on the tensioner pulley and turn the tensioner counterclockwise to relieve the tension on the timing belt. Slide the timing belt from the sprockets.

    jturcotte_1820.gif

    Fig. Use the VW tool to lock the camshaft at TDC for timing belt replacement-Volkswagen 1.9L Diesel engines


    jturcotte_1821.gif

    Fig. Locking the injection pump with the VW tool as shown-Volkswagen 1.9L Diesel engines


To install:
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  4. Install the belt cover and accessory drive belts.
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any of the non computerized aka 12 valve cummins will interchange going from the p7100 pump on the 94 to the ve injection pump on the 92 may mean rerouting some of the fuel lines to hook it up. make sure you use all the sensors from the 94 engine though so all your gauges read correctly other than the fuel system the engines are identical though so should have no issues doing this

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