Bosch VE Fuel Pump 4-390 Engines

Section 3415 BOSCH MODEL VE FUEL INJECTION PUMP Pump Drive Gear, Fuel Shutoff Solenoid, Primer Pump and Pump Timing 4-390 Diesel Engine IMPORTANT: This engine was made using the metric measurement system. All measurements and checks must be made with metric tools to make sure of an a accurate reading when inspecting parts. CASE CORPORATION 700 State Street Racine, WI 53404 U.S.A. CASE CANADA CORPORATION © 1999 Case Corporation 450 Sherman Avenue Rac 7-37145 Printed in U.S.A. Hamilton. ON L8N 4C4 CANADA February, 1991 (Revised May, 1999)

3415-2 TABLE OF CONTENTS SPECIALTOOLS ........................................................................................................................................................2 SPECIALTORQUES .................................................................................................................................................... VE Injection Pump LockTiming Chart .................................................................................................................................................... 3 TROUBLESHOOTINGGUIDE ....................................................................................................................................... 4 FUELINJECTION PUMP .............................................................................................................................................. 5 Removal................................................................................................................................................................. Installation.............................................................................................................................................................. 7 INJECTIONPUMP GEAR ............................................................................................................................................. 8 Removal................................................................................................................................................................. 8 Installation............................................................................................................................................................ 11 INJECTIONPUMP TIMING ......................................................................................................................................... 12 FUELSHUT-OFF SOLENOID ...................................................................................................................................... 17 Removaland Disassembly ...................................................................................................................................... 17 Assemblyand Installation ........................................................................................................................................ 18 PRIMERPUMP ......................................................................................................................................................... 18 Removal............................................................................................................................................................... 18 Installation............................................................................................................................................................ 19 TIMINGLOCKING PIN ............................................................................................................................................... 19 Removal............................................................................................................................................................... 19 Installation............................................................................................................................................................ 20 SPECIAL TOOLS CAS-1690 ENGINE TURNOVER TOOL CAS-2521 GEAR PULLER CAS-1145 DIAL INDICATOR Rac 7-31145 Revised 5-99 Printed in U.S.A

3415-3 SPECIAL TORQUES Injection Pump Mounting Bolts ........................................................................................................................................ 21 to 27 Nm Injection Pump Drive Gear Nut ........................................................................................................................................ 59 to 71 Nm FuelLine Inlet Bolt .......................................................................................................................................................... 22 to 28 Nm FuelShut-off Solenoid .............................................................................................................................................................. 43 Nm LeakOff Fitting ................................................................................................................................................................ 1310 17 Nm Injection Pump Lock Bolt, Lock Position ........................................................................................................................... 2] to 33 Nm Injection Pump Lock Bolt, Unlock Position ....................................................................................................................... 12 to 14 Nm VE Injection Pump Lock Timing Chart MACHINE MODEL ENGINE MODEL Plunger Lift @ TDC 450, 455, W11B 41-390 2.00 860, 580K, 4T-390 IPU, 9OXTE, 95XTE 4T-390 1.80 90XT, 95XT 41-390 1.80 650 41-390 1.80 580SL, 58OSLE 41-390 1.80 590SL, 5120, 5220 41-390 1.55 688, 788, 9010 41-390 1.80 8225, 8840 41-390 1.80 1840,1845C 41-390 1.25 9020, 9010B. 9020B 4TA-390 1.55 Rac 7-37145 Revised 5-99 Printed in U.S.A

3415-4 TROUBLESHOOTING GUIDE NOTE: It is assumed that the engine is in good working order and properly tuned, and the electrical system has beer checked and repaired as necessary. ) C) 0 E = ' 0 CL (I) - D .9 0 CD CL Ca - 0 E _J E 0 Cn 000 ci) ) CD E < C-) - 0 (1) -= /) CD = = CD 0 c ° C > (_) -- D) L) _ - 0 Ln In C) CL 0) 0) 0 0 0 __J = CM 0 = ) 0 C.) &) = u C 0 u 0 - >C Lu 0 Lu 0 0 0 u .E uj CAUSE AND REMEDY - Incorrect fuel in the fuel tank: Drain tank, flush system and fill with correct fuel - - - Fuel tank empty or fuel tank vent blocked: Fill tank and bleed system, check tank vent (Refer to Section 3410) Air in the fuel system: Bleed fuel system, eliminate air leaks (Refer to Section 3410) - Pump rear support bracket loose: Replace as necessary - Voltage supply malfunction, stop solenoid defective: Correct electrical faults, replace solenoid (Refer to Section 3414) Fuel filter blocked: Replace fuel filter (Refer to Section 3410) Fuel supply lines blocked or restricted: Check all fuel supply line, flush or replace Loose connection, injection lines leaking or broken: Tighten the connection, eliminate the leak Paraffin deposit in fuel filter: Replace filter, use Diesel Fuel No. 1 (Refer to Operators Manual) Fuel injection pump timing incorrect: Adjust timing Injection nozzle faulty: Repair or replace (Refer to Section 3413) Engine air filter blocked: - - Replace air filter element - Injection sequence does not correspond to firing order: - - - Install fuel injection lines in the correct order (Refer to Section 3414) Overflow fitting interchanged with inlet fitting: - - - Install fittings in correct positions (Refer to Section 3414) - Cold-start device malfunction (if equipped): Check cold-start mechanism (if equipped) - Low or uneven engine compression: Repair as necessary (Refer to Section 2425) 77 Fuel injection pump defective or cannot be adjusted: - Replace (Refer to Section 3414) Rac 7-37145 Revised 5-99 Printed in U.S.A.

3.. I Remove the nut and washer from the injection pump drive shaft 3415-5 FUEL INJECTION PUMP Removal STEP 1 STEP 4 L Clean the area around the fuel Injection pump. Disconnect and remove the fuel injector tubes. STEP 2 Disconnect and remove the fuel inlet tube. STEP 3 Remove the leak off fitting. Remove and discard the sealing vashers. Remove the tachometer drive assembly (it equipped). STEP 5 Rac 7-37145 Revised 5-99 Printed in U.S.A.

Make a mark on the injection pump flange and front housing for alignment during assembly. Install the engine turn over tool, and push in on the locking pin. Turn the engine over until the locking pin engages in the camshaft gear. STEP 7 1 I,- I - . T78811 Loosen the pump shaft lock bolt and remove the slotted tab. Rac 7-37145 STEP 8 J w/ I1Ti 8 Tighten the pump shaft lock bolt to a torque of 27 to 33 Nm. STEP 9 Install the gear puller and tighten the bolts until the gear is loose from the pump shaft. STEP 10 _J J1 - \788 15 Remove the pump retaining nuts and bolt and remove the pump. IMPORTANT: Care must be taken when removing the pump from the gear not to lose the key from the pump shaft. If the key is not on the shaft, it is necessary to remove the timing cover. Revised 5-99 Printed in U.S.A.

3415-7 Installation STEP 11 VT STEP 14 I _ • :V '.. I I Install a new gasket. Install the injection pump. Install the injection pump washer and nut. NOTE: Make sure the key in the injection pump shaft and the slot in the drive gear are aligned. STEP 12 \ I - -- T788 14 Align the marks on the injection pump flange and front housing. Install the pump retaining nuts and bolt. Install the bolt into pump mounting bracket. Tighten the nuts and bolts to a torque of 21 to 27 Nm. STEP 13 I 178811 k. - Install the slotted tab and tighten the lock bolt to a torque of 12 to 14 Nm. Rac 7-37145 I 1 178797 Pull out the locking pin from the camshaft gear. STEP 15 Install the nut and washer on the injection pump safety. Tighten the nut to a torque of 59 to 71 Nm. STEP 16 Install the tachometer drive assembly (it equipped). NOTE: The nut on the injection pump and the tachometer drive nut must be aligned. Revised 5-99 Printed in U.S.A.

3415-8 STEP 17 STEP 19 Remove the caps. Install the leak off fitting and new sealing washers. Tighten the fitting to a torque of 1310 17 Nm. STEP 18 Remove the caps. Install and tighten the tubes between the fuel injectors and fuel injection pump. Install the fuel inlet fitting with new sealing washers. Tighten the fitting to a torque of 22 to 28 Nm. INJECTION PUMP GEAR Removal STEP 20 STEP 21 ri99cl 33 Lift the belt tensioner and remove the fan belt. Remove the crankshaft pulley retaining bolts and crankshaft pulley. Rac 7-37145 Revised 5-99 Printed in U.S.A.

STEP 22 Remove the front cover bolts and the front cover. STEP 23 Loosen the nut on the injection pump shaft. 3415-9 STEP 24 j ( Ake H \ \J Install the engine turn over tool and turn the engine in a clockwise direction as viewed from the front of the engine until the locking pin engages the camshaft gear. Rac 7.37145 Revised 5-99 Printed in U.S.A.

3415-10 STEP 25 Loosen the lock bolt and remove the slotted tab. STEP 26 1' Tighten the lock bolt (1) to a torque of 27 tO 33 Nm, STEP 27 A111 IItIIII._""' 178828 Remove the nut and washer from the injection pump shaft. STEP 28 Install the gear puller and tighten the bolts until the gear is loose on the injection pump. Rac 7-31145 Revised 5-99 Printed in U.S.A.

Bosch VE Fuel Pump 4-390 Engines

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